Systems, devices, and methods for rail-based and other electric motor vehicles with modular cascaded energy systems

Abstract

Exemplary embodiments of systems, devices, and methods are provided for electric vehicles that undergo intermittent charging, such as rail-based electric vehicles, having one or more modular cascaded energy systems. The one or more modular systems can be configured to supply polyphase, single-phase, and / or DC power to multiple motors and auxiliary loads of the EV. When multiple systems or subsystems are present in the EV, they can be interconnected to exchange energy between them in a number of different ways, such as through lines designated to carry power from an intermittently connected charging source, interconnected between arrays of subsystems, through the presence of modules, etc.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 025,099, filed May 14, 2020, U.S. Provisional Application No. 63 / 029,368, filed May 22, 2020, and U.S. Provisional Application No. 63 / 084,293, filed September 28, 2020, all of which are incorporated herein by reference in their entirety and for all purposes.

[0002] The subject matter described herein generally relates to systems, devices, and methods for rail-based and other electric motor vehicles having modular cascaded energy systems. [Background technology]

[0003] For electric vehicles operating on rails, power to drive the electric motors is provided by a charging source. This charging source is typically in the form of a high-voltage conductor that resides along a section of track. The charging source can be an overhead line such as a suspension wire, a ground-level power source such as a third rail, or an underground source such as a conduit. Rail-based EVs receive power from this charging source using a conductive element (e.g., a pantograph or plow) that remains in continuous contact with the charging source as the EV moves. In some cases, rail-based EVs use a static approach, extending a conductor and contacting the charging source when the vehicle is stopped, charging while the vehicle is not moving, and then removing the conductor from contact with the charging source prior to resuming movement.

[0004] Charging lines that are permanently installed along the rails require additional physical space and infrastructure, can be unsightly, can pose risks to the public in the environment, and are costly to build and maintain in a safety manner. Conventional rail-based EVs can be configured with energy storage systems that store power to operate the motors and allow the rail-based EVs to traverse sections of rail where no charging sources exist. However, these rail-based EVs suffer from limitations in range, limitations in the lifespan of the energy source, and can lack flexibility in implementation for rail-based EVs with numerous motors and auxiliary loads requiring power.

[0005] Therefore, there is a need for improved energy systems for use in rail-based electric motor vehicles and related vehicles and stationary applications. Summary of the Invention [Means for solving the problem]

[0006] Exemplary embodiments of systems, devices, and methods for electric vehicles that undergo intermittent charging, such as rail-based electric vehicles, having one or more modular cascaded energy systems are provided herein. The one or more modular systems can be configured to supply polyphase, single-phase, and / or DC power to multiple motor and auxiliary loads of the EV. When multiple systems or subsystems are present in the EV, they can be interconnected to exchange energy between them in a number of different ways, such as through lines designated to carry power from an intermittently connected charging source, or through the presence of modules interconnected between arrays of subsystems. The subsystems can be configured as subsystems that supply power for motor loads only, motor loads combined with auxiliary loads, and auxiliary loads only.

[0007] Each module of the subsystem can be configured with multiple converters and one or more energy sources so that the module can receive a relatively high-voltage signal from an intermittently connected charging source, modify that voltage with one or more converters, and charge one or more energy sources, and the module can utilize another converter to convert DC voltage from the one or more energy sources to an AC output voltage for powering one or more loads on the EV. Charging can occur while the EV is moving, such as with a rail-based EV receiving power from an overhead, ground-level, or underground charging source. Embodiments are applicable to other applications as well.

[0008] Other systems, devices, methods, features, and advantages of the subject matter described herein will be, or become, apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this description, be within the scope of the subject matter described herein, and be protected by the accompanying claims. Features of the exemplary embodiments should not be construed as limiting the appended claims in any way absent express recitation of those features in the claims. The present invention provides, for example, the following. (Item 1) 1. A modular energy system controllable to supply electrical power to a load, comprising: a plurality of modules connected together to output an AC voltage signal comprising a superposition of a first output voltage from each module; Each module comprises: An energy source, a first converter connected to the energy source and configured to generate the first output voltage at a first port of the module; a second converter connected between a second port of the module and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a second output voltage, and charge the energy source; A system comprising: (Item 2) Item 10. The system of item 1, wherein the first converter comprises a plurality of switches. (Item 3) Item 3. The system of item 2, wherein the plurality of switches are configured as a full-bridge converter. (Item 4) Item 10. The system of claim 1, wherein the second converter is a DC-DC converter comprising a transformer configured to isolate the energy source and the first converter from the second port. (Item 5) Item 5. The system of item 4, wherein the second converter comprises a DC-AC converter connected between the second port and the transformer. (Item 6) Item 6. The system of item 5, wherein the second converter comprises a diode rectifier connected between the transformer and the energy source. (Item 7) Item 5. The system of item 4, wherein the second converter comprises an AC-DC converter connected between the transformer and the energy source. (Item 8) Item 8. The system of item 7, wherein the AC-DC converter is configured as a full-bridge converter or a push-pull converter. (Item 9) Item 5. The system of item 4, wherein the second converter is a unidirectional converter that conducts electricity from the second port to the energy source. (Item 10) Item 5. The system of item 4, wherein the second converter is a bidirectional converter that conducts electricity between the second port and the energy source. (Item 11) Item 10. The system of item 1, wherein the plurality of modules are connected in series as an array and connected to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module is divided down from the total charging source voltage. (Item 12) 12. The system of any of items 1-11, wherein the energy source is a first energy source and each module is equipped with a second energy source. (Item 13) Item 13. The system of item 12, wherein the second energy source is connected to the first converter by an inductor. (Item 14) Item 13. The system of item 12, wherein the first energy source is a lithium ion battery of a first type and the second energy source is a lithium ion battery of a second type, and the first and second types are different. (Item 15) Item 13. The system of item 12, wherein the first energy source is a battery and the second energy source is a high energy density (HED) capacitor. (Item 16) 12. The system of any of items 1-11, wherein each module further comprises an energy buffer connected in parallel with the energy source. (Item 17) Item 17. The system of item 16, wherein the energy buffer is a capacitor. (Item 18) 18. The system of any of items 1-17, further comprising a control system configured to control switching of the first and second converters. (Item 19) 20. The system of claim 18, wherein the control system comprises a plurality of local control devices associated with the plurality of modules, and a master control device communicatively coupled to the plurality of local control devices. (Item 20) Item 19. The system of item 18, wherein the control system is configured to control switching of the second converter of each module to exchange energy between the energy sources of the modules. (Item 21) 1. A modular energy system controllable to supply electrical power to a load, comprising: a first array comprising a first plurality of modules connected together to output a first AC voltage signal comprising a superposition of output voltages from the first plurality of modules; a second array comprising a second plurality of modules connected together to output a second AC voltage signal comprising a superposition of output voltages from the second plurality of modules; each module of the first plurality of modules and the second plurality of modules comprises: An energy source, a first converter connected to the energy source and configured to generate the output voltage at a first port of the module; a second converter connected to a second port of the module and to the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a charging voltage, and charge the energy source; A system comprising: (Item 22) further comprising a first interconnection module coupled to the first array and a second interconnection module coupled to the second array, each of the first and second interconnection modules comprising: a first port and a second port; An energy source, a first converter connected to the energy source and configured to generate an output voltage at the first port; a second converter connected to the second port and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal into a charging voltage, and charge the energy source; Item 22. The system of item 21, comprising: (Item 23) Item 23. The system of item 22, wherein the energy sources of the first and second interconnection modules are connected in parallel. (Item 24) 24. The system of any of items 22-23, wherein the first interconnection module is configured to supply power for an auxiliary load. (Item 25) Item 25. The system of item 24, wherein the first interconnection module comprises a third port configured to connect an energy source of the first interconnection module to an auxiliary load. (Item 26) Item 25. The system of item 24, wherein the first interconnection module includes a third port configured to connect an energy source of the first interconnection module to an auxiliary load external to the first interconnection module through a switch network and an inductor of the first interconnection module. (Item 27) 27. The system of any of items 22-26, further comprising a control system configured to control a first converter of each of the first and second interconnection modules to balance energy between the first array and the second array. (Item 28) 27. The system of any of items 22-26, further comprising a control system configured to control a first converter of each of the first and second interconnection modules to balance energy between the first array and the second array. (Item 29) 22. The system of claim 21, wherein the first converter comprises a plurality of switches. (Item 30) 30. The system of claim 29, wherein the plurality of switches are configured as a full-bridge converter. (Item 31) 22. The system of claim 21, wherein the second converter is a DC-DC converter comprising a transformer configured to isolate the energy source and the first converter from the second port. (Item 32) Item 32. The system of item 31, wherein the second converter comprises a DC-AC converter connected between the second port and the transformer. (Item 33) Item 33. The system of item 32, wherein the second converter comprises a diode rectifier connected between the transformer and the energy source. (Item 34) Item 32. The system of item 31, wherein the second converter comprises an AC-DC converter connected between the transformer and the energy source. (Item 35) Item 35. The system of item 34, wherein the AC-DC converter is configured as a full-bridge converter or a push-pull converter. (Item 36) Item 32. The system of item 31, wherein the second converter is a unidirectional converter that conducts electricity from the second port to the energy source. (Item 37) Item 32. The system of item 31, wherein the second converter is a bidirectional converter that conducts electricity between the second port and the energy source. (Item 38) 22. The system of claim 21, wherein the first plurality of modules are connected in series within the first array and connected to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of the first array is divided from the total charging source voltage. (Item 39) 39. The system of any of items 21-38, wherein the energy source is a first energy source and each module is provided with a second energy source. (Item 40) Item 40. The system of item 39, wherein the second energy source is connected to the first converter by an inductor. (Item 41) Item 40. The system of item 39, wherein the first energy source is a lithium ion battery of a first type and the second energy source is a lithium ion battery of a second type, and the first and second types are different. (Item 42) Item 40. The system of item 39, wherein the first energy source is a battery and the second energy source is a high energy density (HED) capacitor. (Item 43) A system described in any of items 21-38, wherein each module of the first plurality of modules, each module of the second plurality of modules, the first interconnection module, and the second interconnection module further comprise an energy buffer connected in parallel with the energy source. (Item 44) Item 44. The system of item 43, wherein the energy buffer is a capacitor. (Item 45) 45. The system of any of items 21-44, further comprising a control system configured to control switching of the first and second converters. (Item 46) Item 46. The system of item 45, wherein the control system comprises a plurality of local control devices associated with the plurality of modules, and a master control device communicatively coupled to the plurality of local control devices. (Item 47) Item 46. The system of item 45, wherein the control system is configured to control switching of the second converter of each module to exchange energy between the energy sources of the modules. (Item 48) 1. A modular energy system controllable to supply electrical power to a load of an electric vehicle, comprising: a first plurality of modules connected together in first, second, and third arrays, each array configured to output an AC voltage signal comprising a superposition of output voltages from the modules of that array; a second plurality of modules connected together in a fourth array and configured to output an AC voltage signal comprising a superposition of the output voltages from the second plurality of modules; Equipped with the first plurality of modules are configured to provide three-phase power to a first auxiliary load of the electric vehicle; The modular energy system, wherein the second plurality of modules is configured to provide single-phase power to a second auxiliary load of the electric vehicle. (Item 49) Item 49. The modular energy system of item 48, further comprising a plurality of interconnection modules connected to the first, second, third, and fourth arrays. (Item 50) Item 50. The modular energy system of item 49, wherein a first interconnection module of the plurality of interconnection modules is configured to provide DC power to a third auxiliary load of the electric vehicle. (Item 51) Item 51. The system of item 50, wherein the first interconnection module comprises an energy source and is configured to connect the energy source to the third auxiliary load. (Item 52) Item 51. The system of item 50, wherein the first interconnection module comprises an energy source and is configured to connect the energy source to the third auxiliary load through a switch network and an inductor of the first interconnection module. (Item 53) All of the above modules individually: An energy source, a first converter connected to the energy source and configured to generate the output voltage at a first port of the module; a second converter connected to a second port of the module and to the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a charging voltage, and charge the energy source; 51. The modular energy system according to any one of items 48-50, comprising: (Item 54) Item 54. The system of item 53, further comprising a control system configured to control a first converter of each of the plurality of interconnection modules to balance energy between the first, second, third, and fourth arrays. (Item 55) Item 54. The system of item 53, wherein the modules of the first array are connected in series to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of the first array is divided down from the total charging source voltage. (Item 56) Item 54. The system of item 53, wherein the first array, second array, and third array are connected in parallel to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of each array is divided from the total charging source voltage. (Item 57) 57. The system of any of items 48-56, wherein all modules further comprise an energy buffer. (Item 58) Item 58. The system of item 57, wherein the energy buffer is a capacitor. (Item 59) 59. The system of any of items 48-58, further comprising a control system configured to control each of the modules. (Item 60) 1. A rail-based electric motor vehicle, comprising: 50. A rail-based electric vehicle comprising a modular energy system controllable to supply electrical power to a load of the rail-based electric vehicle, the modular energy system being configured according to any of items 1-47. (Item 61) 61. A rail-based electric vehicle according to item 60 configured as a railcar or tram. (Item 62) Item 61. The rail-based electric vehicle of item 60, configured to connect intermittently to a charging source while in motion. (Item 63) Item 63. The rail-based electric vehicle of item 62, wherein the charging source is an overhead catenary. (Item 64) 64. A rail-based electric vehicle according to any one of items 60-63, wherein the load is an electric motor. (Item 65) 1. A rail-based electric motor vehicle, comprising: 59. A rail-based electric vehicle comprising a modular energy system controllable to supply electrical power to loads of the rail-based electric vehicle, the modular energy system being configured according to any of items 48-59. (Item 66) 65. A rail-based electric vehicle as described in item 65, configured as a railcar or tram. (Item 67) Item 66. The rail-based electric vehicle of item 65, configured to connect intermittently to a charging source while in motion. (Item 68) Item 68. The rail-based electric vehicle of item 67, wherein the charging source is an overhead catenary. (Item 69) An electric motor vehicle, a first modular energy system controllable to supply electrical power to a load of a rail-based electric vehicle, the first modular energy system being configured according to any of items 1-47, and the load being an electric motor; and a second modular energy system controllable to supply electrical power to auxiliary loads of the rail-based electric vehicle, the second modular energy system being configured according to any of items 48-59; and An electric vehicle comprising: (Item 70) 1. A modular energy system controllable to supply electrical power to a load, comprising: a plurality of modules connected together and outputting an AC voltage signal comprising a superposition of first output voltages from each module, each module comprising: an energy source; a first converter connected to the energy source and configured to generate the first output voltage at a first port of the module; and a second converter connected between a second port of the module and the energy source; a control system configured to control the first converter and the second converter of each module; A system comprising: (Item 71) Item 71. The system of item 70, wherein the control system is configured to control the first converter of each module to output the first output voltage according to a pulse width modulation technique. (Item 72) Item 72. The system of item 71, wherein the control system is configured to control the second converter of each module to charge the energy source of the module. (Item 73) Item 71. The system of item 70, wherein the control system is configured to control the second converter of each module to charge the energy source of the module, and in parallel to control the first converter of each module to output the first output voltage. (Item 74) 74. The system of items 72 and 73, wherein at least a subset of modules of the plurality of modules are connected together in a cascaded manner such that a first port of each module in the subset is coupled to a first port of another module in the subset and a second port of each module in the subset is coupled to a second port of another module in the subset. (Item 75) Item 75. The system of item 74, wherein the control system is configured to control a second converter of a first module in the plurality of modules and a second converter of a second module in the plurality of modules to exchange energy between an energy source of the first module and an energy source of the second module. (Item 76) 76. The system of any of items 70-75, wherein the second converter of each module of the plurality of modules is a DC-DC converter comprising a transformer configured to isolate the energy source and the first converter from the second port. (Item 77) Item 77. The system of item 76, wherein the second converter of each module of the plurality of modules comprises a DC-AC converter connected between the second port and the transformer. (Item 78) Item 78. The system of item 77, wherein the second converter of each module of the plurality of modules comprises a diode rectifier connected between the transformer and the energy source. (Item 79) Item 78. The system of item 77, wherein the second converter of each module of the plurality of modules comprises an AC-DC converter connected between the transformer and the energy source. (Item 80) 80. The system of claim 79, wherein the AC-DC converter is configured as a full-bridge converter or a push-pull converter. (Item 81) 81. A system according to any of items 70-80, wherein the energy source is a first energy source, and each module of the plurality of modules comprises a second energy source coupled to the first converter using an inductor. (Item 82) A system described in any of items 70-81, wherein the control system comprises a plurality of local control devices associated with the plurality of modules and a master control device communicatively coupled to the plurality of local control devices. (Item 83) 83. The system of any of items 70-82, wherein the first plurality of modules are connected together in first, second, and third arrays, each configured to output an AC voltage signal comprising a superposition of the output voltages from the modules in that array. (Item 84) Item 84. The system of item 83, further comprising a second plurality of modules connected together in fourth, fifth, and sixth arrays, each configured to output an AC voltage signal comprising a superposition of the output voltages from the modules in that array. (Item 85) Item 85. The system of item 84, further comprising a third plurality of modules, the third plurality of modules connected together in a seventh array and configured to output an AC voltage signal comprising a superposition of output voltages from the third plurality of modules. (Item 86) Item 86. The system of item 85, wherein the first plurality of modules is configured to provide three-phase power to a motor of the electric vehicle, the second plurality of modules is configured to provide three-phase power to a first auxiliary load of the electric vehicle, and the third plurality of modules is configured to provide single-phase power to a second auxiliary load of the electric vehicle. (Item 87) Item 87. The modular energy system of item 86, wherein the control system is configured to control a first converter and a second converter of each module of the second and third pluralities of modules. (Item 88) 85. The modular energy system of any of items 70-77 and 79-85, further comprising an auxiliary converter coupled to a DC line of the system, the auxiliary converter configured to convert DC power from the DC line to AC power for an auxiliary load. (Item 89) Item 89. The modular energy system of item 88, wherein the control system is configured to control the second converter of each module so that the output DC voltage is applied to the DC line to power the auxiliary converter, and output the DC voltage from the second port of each module. (Item 90) 1. A method of operating a rail-based electric vehicle with a modular energy storage system, the method comprising: outputting an AC power signal comprising a plurality of first output voltages from a plurality of modules to an electric motor of the rail-based electric vehicle, each of the plurality of modules comprising: an energy source; a first converter coupled to the energy source and configured to output the first output voltage from a first port of the module; and a second converter coupled between the energy source and a second port of the module; applying a charging signal to the electric vehicle, a voltage from the charging signal being applied to a second port of each of the plurality of modules; controlling a second converter of each of the plurality of modules to charge an energy source of each module; A method comprising: (Item 91) Item 89. The method of item 88, wherein the electric vehicle is moving while the charging signal is applied. (Item 92) Item 89. The method of item 88, wherein the modular energy storage system is configured according to any of items 1-47. [Brief explanation of the drawings]

[0009] Details of the subject matter described herein, both as to its structure and operation, may be apparent by consideration of the accompanying drawings, in which like reference numerals refer to like parts. The components within the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Moreover, all illustrations are intended to convey concepts in which relative size, shape, and other detailed attributes may be depicted diagrammatically, rather than literally or precisely.

[0010] [Figure 1A] 1A-1C are block diagrams depicting exemplary embodiments of modular energy systems. [Figure 1B] 1A-1C are block diagrams depicting exemplary embodiments of modular energy systems. [Figure 1C] 1A-1C are block diagrams depicting exemplary embodiments of modular energy systems.

[0011] [Figure 1D]1D-1E are block diagrams depicting exemplary embodiments of control devices for energy systems. [Figure 1E] 1D-1E are block diagrams depicting exemplary embodiments of control devices for energy systems.

[0012] [Figure 1F] 1F-1G are block diagrams depicting exemplary embodiments of a modular energy system coupled with a load and a charging source. [Figure 1G] 1F-1G are block diagrams depicting exemplary embodiments of a modular energy system coupled with a load and a charging source.

[0013] [Figure 2A] 2A-2B are block diagrams depicting exemplary embodiments of modules and control systems within an energy system. [Figure 2B] 2A-2B are block diagrams depicting exemplary embodiments of modules and control systems within an energy system.

[0014] [Figure 2C] FIG. 2C is a block diagram depicting an exemplary embodiment of the physical configuration of the modules.

[0015] [Figure 2D] FIG. 2D is a block diagram depicting an exemplary embodiment of the physical configuration of a modular energy system.

[0016] [Figure 3A] 3A-3C are block diagrams depicting exemplary embodiments of modules having various electrical configurations. [Figure 3B] 3A-3C are block diagrams depicting exemplary embodiments of modules having various electrical configurations. [Figure 3C]3A-3C are block diagrams depicting exemplary embodiments of modules having various electrical configurations.

[0017] [Figure 4] 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources.

[0018] [Figure 5] 5A-5C are schematic diagrams depicting exemplary embodiments of energy buffers.

[0019] [Figure 6A] 6A-6C are schematic diagrams depicting exemplary embodiments of converters. [Figure 6B] 6A-6C are schematic diagrams depicting exemplary embodiments of converters. [Figure 6C] 6A-6C are schematic diagrams depicting exemplary embodiments of converters.

[0020] [Figure 7-1] 7A-7E are block diagrams depicting exemplary embodiments of modular energy systems having various topologies. [Figure 7-2] 7A-7E are block diagrams depicting exemplary embodiments of modular energy systems having various topologies.

[0021] [Figure 8A] FIG. 8A is a plot depicting an example output voltage of the module.

[0022] [Figure 8B] FIG. 8B is a plot depicting an exemplary multi-level output voltage of an array of modules.

[0023] [Figure 8C] FIG. 8C is a plot depicting exemplary reference and carrier signals that can be used in a pulse width modulation control technique.

[0024] [Figure 8D] FIG. 8D is a plot depicting exemplary reference and carrier signals that can be used in a pulse width modulation control technique.

[0025] [Figure 8E] FIG. 8E is a plot depicting an exemplary switch signal generated according to a pulse width modulation control technique.

[0026] [Figure 8F] FIG. 8F is a plot depicting an exemplary multi-level output voltage generated by superposition of output voltages from an array of modules under pulse width modulation control techniques.

[0027] [Figure 9] 9A-9B are block diagrams depicting exemplary embodiments of a controller for a modular energy system.

[0028] [Figure 10A] FIG. 10A is a block diagram depicting an exemplary embodiment of a multi-phase modular energy system having interconnected modules.

[0029] [Figure 10B] FIG. 10B is a schematic diagram depicting an exemplary embodiment of an interconnection module in the multi-phase embodiment of FIG. 10A.

[0030] [Figure 10C] FIG. 10C is a block diagram depicting an exemplary embodiment of a modular energy system having two subsystems connected together by an interconnection module.

[0031] [Figure 10D]FIG. 10D is a block diagram depicting an exemplary embodiment of a three-phase modular energy system having interconnected modules supplying auxiliary loads.

[0032] [Figure 10E] FIG. 10E is a schematic diagram depicting an exemplary embodiment of an interconnection module in the multi-phase embodiment of FIG. 10D.

[0033] [Figure 10F] FIG. 10F is a block diagram depicting another exemplary embodiment of a three-phase modular energy system having interconnected modules supplying auxiliary loads.

[0034] [Figure 11A] FIG. 11A is an illustration depicting an example route for an electric rail-based vehicle.

[0035] [Figure 11B] FIG. 11B is a block diagram depicting an exemplary embodiment of an electrical layout of a modular energy system for an electric rail-based vehicle.

[0036] [Figure 11C] FIG. 11C is a side view depicting an exemplary embodiment of an electrical layout of a modular energy system for an electric rail-based vehicle.

[0037] [Figure 11D] FIG. 11D is a block diagram depicting another example embodiment of an electrical layout of a modular energy system for an electric rail-based vehicle.

[0038] [Figure 11E] FIG. 11E is a side view depicting another exemplary embodiment of an electrical layout of a modular energy system for an electric rail-based vehicle.

[0039] [Figure 11F] FIG. 11F is a block diagram depicting another exemplary embodiment of an electrical layout of a modular energy system for an electric rail-based vehicle.

[0040] [Figure 12] 12A-12B are block diagrams depicting exemplary embodiments of modules for use in modular energy systems.

[0041] [Figure 13A] 13A-13C are schematic diagrams depicting exemplary embodiments of modules for use in modular energy systems. [Figure 13B] 13A-13C are schematic diagrams depicting exemplary embodiments of modules for use in modular energy systems. [Figure 13C] 13A-13C are schematic diagrams depicting exemplary embodiments of modules for use in modular energy systems.

[0042] [Figure 14A] 14A-14B are block diagrams depicting exemplary embodiments of modular energy system topologies. [Figure 14B] 14A-14B are block diagrams depicting exemplary embodiments of modular energy system topologies.

[0043] [Figure 14C] 14C-14D are schematic diagrams depicting exemplary embodiments of interconnection modules for use in modular energy systems. [Figure 14D] 14C-14D are schematic diagrams depicting exemplary embodiments of interconnection modules for use in modular energy systems.

[0044] [Figure 15]FIG. 15 is a block diagram depicting an exemplary embodiment of a modular energy system topology.

[0045] [Figure 16] FIG. 16 is a schematic diagram depicting another exemplary embodiment of an interconnection module. DETAILED DESCRIPTION OF THE INVENTION

[0046] Detailed Description Before the present subject matter is described in detail, it is to be understood that this disclosure is not limited to particular embodiments described, as such may, of course, vary. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, as the scope of the present disclosure will be limited only by the appended claims.

[0047] Before describing exemplary embodiments of modular energy systems implemented in rail-based and other applications that rely on intermittent charging, it is useful to first describe these underlying systems in more detail. With reference to Figures 1A-10F, the following sections describe various application in which modular energy system embodiments may be implemented, control system or device embodiments for the modular energy system, configuration of modular energy system embodiments relative to charging sources and loads, embodiments of individual modules, embodiments of topologies for arrangement of modules within the system, embodiments of control methodologies, embodiments of balanced operating characteristics of modules within the system, and embodiments of use of interconnected modules. Examples of uses

[0048] Stationary applications are those in which a modular energy system resides at a fixed location during use but may be capable of being transported to an alternative location when not in use. The module-based energy system provides electrical energy for consumption by one or more other entities or stores or buffers energy for later consumption while residing at a static location. Examples of stationary applications in which embodiments disclosed herein may be used include, but are not limited to, energy systems for use by or within one or more residential structures or locations, energy systems for use by or within one or more industrial structures or locations, energy systems for use by or within one or more commercial structures or locations, energy systems for use by or within one or more government structures or locations (including both military and non-military uses), energy systems for charging mobile applications described below (e.g., charging sources or charging stations), and systems that convert solar power, wind power, geothermal energy, fossil fuels, or nuclear reactions into electricity for storage. Stationary applications often supply loads such as grids and microgrids, motors, and data centers. Stationary energy systems can be used in either storage or non-storage roles.

[0049] Mobile applications, sometimes referred to as traction applications, generally involve a modular energy system located on or within an entity that stores and provides electrical energy for conversion into motive power by a motor to move or assist in moving the entity. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, electric and / or hybrid entities that travel over land or underground, over or under the sea, above land or sea without contact therewith (e.g., flying or hovering in the air), or through space. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, cars, trains, trams, ships, watercraft, aircraft, and spacecraft. Examples of mobile vehicles with which the embodiments disclosed herein may be used include, but are not limited to, those with only one wheel or track, those with only two wheels or tracks, those with only three wheels or tracks, those with only four wheels or tracks, and those with five or more wheels or tracks. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, cars, buses, railroad tracks, motorcycles, scooters, industrial vehicles, mining vehicles, air vehicles (e.g., airplanes, helicopters, drones, etc.), watercraft (e.g., commercial transport vessels, ships, yachts, boats, or other water vehicles), submarines, locomotives or rail-based vehicles (e.g., trains, etc.), military vehicles, spacecraft, and satellites.

[0050] In describing embodiments herein, reference may be made to a particular stationary application (e.g., a grid, a microgrid, a data center, a cloud computing environment) or a mobile application (e.g., an electric vehicle). Such references are made for ease of explanation and do not imply that a particular embodiment is limited for use only in that particular mobile or stationary application. Embodiments of a system for providing power to a motor can be used in both mobile and stationary applications. While certain configurations may be more suitable for some applications than others, all exemplary embodiments disclosed herein are capable of use in both mobile and stationary applications unless otherwise stated. Example of a module-based energy system

[0051] FIG. 1A is a block diagram depicting an exemplary embodiment of a module-based energy system 100. Here, system 100 includes a control system 102 communicatively coupled to N converter source modules 108-1 through 108-N via communication paths or links 106-1 through 106-N, respectively. The modules 108 are configured to store energy and output energy to a load 101 (or other modules 108) as needed. In these embodiments, any number of two or more modules 108 can be used (e.g., N is greater than or equal to two). The modules 108 can be interconnected in various manners, as will be described in further detail with respect to FIGS. 7A-7E. For ease of illustration, in FIGS. 1A-1C, the modules 108 are shown connected in series or as a one-dimensional array, with the Nth module coupled to the load 101.

[0052] System 100 is configured to supply power to load 101. Load 101 can be any type of load, such as a motor or a grid. System 100 is also configured to store power received from a charging source. FIG. 1F is a block diagram depicting an exemplary embodiment of system 100 with a power input interface 151 for receiving power from charging source 150 and a power output interface for outputting power to load 101. In this embodiment, system 100 can receive and store power via interface 151 while simultaneously outputting power via interface 152. FIG. 1G is a block diagram depicting another exemplary embodiment of system 100 with a switchable interface 154. In this embodiment, system 100 can select, or be instructed to select, between receiving power from charging source 150 and outputting power to load 101. The system 100 can be configured to supply multiple loads 101, including both primary and auxiliary loads, and / or receive power from multiple charging sources 150 (e.g., a utility grid and local renewable energy sources (e.g., solar)).

[0053] 1B depicts another exemplary embodiment of system 100. Here, control system 102 is implemented as a master control device (MCD) 112 that is communicatively coupled to N different local control devices (LCDs) 114-1-114-N via communication paths or links 115-1-115-N, respectively. Each LCD 114-1-114-N is communicatively coupled to one module 108-1-108-N via communication paths or links 116-1-116-N, respectively, such that a 1:1 relationship exists between the LCD 114 and the module 108.

[0054] 1C depicts another exemplary embodiment of system 100. Here, MCD 112 is communicatively coupled to M different LCDs 114-1 to 114-M via communication paths or links 115-1 to 115-M, respectively. Each LCD 114 is coupled to and can control two or more modules 108. In the example shown, here, each LCD 114 is communicatively coupled to two modules 108, such that MCDs 114-1 to 114-M are coupled to 2M modules 108-1 to 108-2M via communication paths or links 116-1 to 116-2M, respectively.

[0055] The control system 102 can be configured as a single device for the entire system 100 (e.g., FIG. 1A), or can be distributed or implemented across multiple devices (e.g., FIGS. 1B-1C). In some embodiments, the control system 102 can be distributed among the LCDs 114 associated with the modules 108, such that any MCDs 112 are not required and may be omitted from the system 100.

[0056] Control system 102 can be configured to perform control using software (instructions stored in memory executable by processing circuitry), hardware, or a combination thereof. One or more devices of control system 102 may each include processing circuitry 120 and memory 122, as shown here. Exemplary implementations of processing circuitry and memory are described further below.

[0057] The control system 102 may have a communication interface for communicating with devices 104 external to the system 100 via communication links or paths 105. For example, the control system 102 (e.g., the MCD 112) may output data or information about the system 100 to another control device 104 (e.g., an electronic control unit (ECU) or motor control unit (MCU) of a vehicle in a mobile application, a grid controller in a stationary application, etc.).

[0058] Each of the communication paths or links 105, 106, 115, 116, and 118 (FIG. 2B) can be a wired (e.g., electrical, optical) or wireless communication path that communicates data or information bidirectionally, in parallel or serial fashion. Data can be communicated in a standardized (e.g., IEEE, ANSI) or custom (e.g., proprietary) format. In automotive applications, the communication path 115 can be configured to communicate according to the FlexRay or CAN protocol. The communication paths 106, 115, 116, and 118 also provide wired power and can directly supply operating power for the control system 102 from one or more modules 108. For example, operating power for each LCD 114 can be supplied solely by the one or more modules 108 to which the LCD 114 is connected, while operating power for the MCD 112 can be indirectly supplied from one or more of the modules 108 (e.g., through the vehicle's power network, etc.).

[0059] The control system 102 is configured to control one or more modules 108 based on status information received from the same or different one or more of the modules 108. The control can also be based on one or more other factors, such as the requirements of the load 101. Controllable aspects include, but are not limited to, one or more of the voltage, current, phase, and / or output power of each module 108.

[0060] Status information for all modules 108 in system 100 can be communicated to control system 102, which can independently control all modules 108-1...108-N. Other variations are possible. For example, a particular module 108 (or a subset of modules 108) can be controlled based on status information for that particular module 108 (or subset), based on status information for a different module 108 that is not the particular module 108 (or subset), based on status information for all modules 108 other than the particular module 108 (or subset), based on status information for the particular module 108 (or subset) and status information for at least one other module 108 that is not the particular module 108 (or subset), or based on status information for all modules 108 in system 100.

[0061] The status information can be information about one or more aspects, characteristics, or parameters of each module 108. Types of status information include, but are not limited to, the following aspects of a module 108 or one or more of its components (e.g., energy source, energy buffer, converter, monitor circuitry): the state of charge (SOC) of one or more energy sources of the module (e.g., the level of charge of the energy source relative to its capacity, such as a fraction or percent), the state of health (SOH) of one or more energy sources of the module (e.g., a figure of merit of the condition of the energy source compared to its ideal condition), the temperature of one or more energy sources or other components of the module, the capacity of one or more energy sources of the module, the voltage of one or more energy sources and / or other components of the module, the current of one or more energy sources and / or other components of the module, and / or the presence or absence of a fault in any one or more of the components of the module.

[0062] The LCD 114 can be configured to receive status information from each module 108 or determine status information from monitored signals or data received from or within each module 108 and communicate that information to the MCD 112. In some embodiments, each LCD 114 can communicate raw collected data to the MCD 112, which then algorithmically determines status information based on the raw data. The MCD 112 can then use the module 108 status information to make control decisions, as appropriate. The decisions may take the form of instructions, commands, or other information (such as a modulation index, as described herein) that can be utilized by the LCD 114 to either maintain or adjust the operation of each module 108.

[0063] For example, the MCD 112 may receive status information, evaluate the information, and determine differences between at least one module 108 (e.g., its components) and at least one or more other modules 108 (e.g., its comparable components). For example, the MCD 112 may determine that a particular module 108 is operating with one of the following conditions compared to one or more other modules 108: a relatively low or high SOC, a relatively low or high SOH, a relatively low or high capacity, a relatively low or high voltage, a relatively low or high current, a relatively low or high temperature, or the presence or absence of a fault. In such an example, the MCD 112 may output control information to reduce or increase (depending on the condition) a relevant aspect (e.g., output voltage, current, power, temperature) of that particular module 108. In this manner, the utilization of an outlier module 108 (e.g., operating with a relatively low SOC or high temperature) can be reduced to cause the relevant parameters (e.g., SOC or temperature) of that module 108 to converge toward those of one or more other modules 108.

[0064] The determination of whether to adjust the operation of a particular module 108 may be made by comparing the status information with predetermined thresholds, limits, or conditions, not necessarily by comparison with the status of other modules 108. The predetermined thresholds, limits, or conditions may be static thresholds, limits, or conditions, such as those set by a manufacturer, that do not change during use. The predetermined thresholds, limits, or conditions may be dynamic thresholds, limits, or conditions that are allowed to change or change during use. For example, the MCD 112 may adjust the operation of a module 108 if the status information for that module 108 indicates that it is violating (e.g., above or below) a predetermined threshold or limit or is operating outside a predetermined range of acceptable operating conditions. Similarly, the MCD 112 may adjust the operation of a module 108 if the status information for that module 108 indicates the presence of an actual or potential fault (e.g., an alarm or warning), or the absence or removal of an actual or potential fault. Examples of faults include, but are not limited to, actual failure of a component, potential failure of a component, short circuits or other excessive current conditions, open circuits, excessive voltage conditions, poor reception of communications, reception of corrupted data, and the like. Depending on the type and severity of the fault, the amount of utilization of the faulty module can be reduced to avoid damaging the module, or utilization of the module can be stopped entirely.

[0065] The MCD 112 can control the modules 108 in the system 100 to achieve or converge toward a desired target. The target can be, for example, that the performance of all modules 108 is at the same or similar level relative to one another, or within a predetermined threshold, limit, or condition. This process can also be referred to as seeking to achieve balance or equilibrium in the operation or operating characteristics of the modules 108. The term “balance,” as used herein, does not require absolute equality between the modules 108 or their components, but rather is used broadly to convey that the operation of the system 100 can be used to actively reduce inequalities in the performance of the modules 108 that would otherwise exist.

[0066] The MCD 112 can communicate control information to the LCD 114 for purposes of controlling the module 108 associated with the LCD 114. The control information can be, for example, a modulation index and reference signal as described herein, a modulated reference signal, or others. Each LCD 114 can use (e.g., receive and process) the control information and generate switch signals that control the operation of one or more components (e.g., converters) in the associated module 108. In some embodiments, the MCD 112 generates the switch signals directly and outputs them to the LCD 114, which relays the switch signals to the intended module components.

[0067] All or a portion of the control system 102 can be combined with a system external control device 104 that controls one or more other aspects of a mobile or stationary application. When integrated within this shared or common control device (or subsystem), control of the system 100 can be implemented in any desired manner, such as one or more software applications executed by processing circuitry of the shared device, hardware of the shared device, or a combination thereof. Non-exhaustive examples of external control device 104 include an on-board ECU or MCU having control capabilities for one or more other on-board functions (e.g., motor control, driver interface control, traction control, etc.), a grid or microgrid controller responsible for one or more other power management functions (e.g., load interfacing, load power requirement prediction, transmission and switching, interfacing with charging sources (e.g., diesel, solar, wind), charging source power prediction, backup source monitoring, asset dispatch, etc.), and a data center control subsystem (e.g., environmental control, network control, backup control, etc.).

[0068] 1D and 1E are block diagrams depicting an example embodiment of a shared or common control device (or system) 132 in which control system 102 may be implemented. In FIG. 1D , common control device 132 includes master control device 112 and external control device 104. Master control device 112 includes interface 141 for communication with LCD 114 via path 115 and interface 142 for communication with external control device 104 via internal communication bus 136. External control device 104 includes interface 143 for communication with master control device 112 via bus 136 and interface 144 for communication with other entities in the overall application (e.g., vehicle or grid components) via communication path 136. In some embodiments, common control device 132 can be integrated as a common housing or package, with devices 112 and 104 implemented as discrete integrated circuit (IC) chips or packages contained therein.

[0069] In FIG. 1E, the external control device 104 acts as a common control device 132, with master control functionality implemented as a component 112 within the device 104. This component 112 can be or include software or other program instructions stored and / or hard-coded within the device 104's memory and executed by its processing circuitry. The component can also contain dedicated hardware. The component can be a self-contained module or core, with one or more internal hardware and / or software interfaces (e.g., application program interfaces (APIs)) for communication with the external control device 104's operating software. The external control device 104 can manage communication with the LCD 114 via interface 141 and with other devices via interface 144. In various embodiments, the devices 104 / 132 can be integrated as a single IC chip, integrated into multiple IC chips in a single package, or integrated as multiple semiconductor packages in a common housing.

[0070] 1D and 1E, the master control functionality of the system 102 is shared within the common device 132; however, other divisions of shared control are also possible. For example, a portion of the master control functionality can be distributed between the common device 132 and the dedicated MCD 112. In another example, both the master control functionality and at least a portion of the local control functionality can be implemented within the common device 132 (e.g., the remaining local control functionality is implemented within the LCD 114). In some embodiments, the control system 102 is implemented entirely within the common device (or subsystem) 132. In some embodiments, the local control functionality is implemented within a device shared with another component of each module 108, such as a battery management system (BMS). Example of a module with a cascaded energy system

[0071] Module 108 can include one or more energy sources, a power electronics converter, and, optionally, an energy buffer. Figures 2A-2B are block diagrams depicting additional exemplary embodiments of system 100 with module 108 having power converter 202, energy buffer 204, and energy source 206. Converter 202 can be a voltage converter or a current converter. While embodiments are described herein with reference to a voltage converter, embodiments are not limited thereto. Converter 202 can be configured to convert a direct current (DC) signal from energy source 204 to an alternating current (AC) signal and output it via power connection 110 (e.g., an inverter). Converter 202 can also receive an AC or DC signal via connection 110 and apply it to energy source 204 with either polarity in a continuous or pulsed form. Converter 202 can be or include an arrangement of switches (e.g., power transistors), such as a half-bridge or full-bridge (H-bridge). In some embodiments, the converter 202 includes only switches, and the converter (and the module as a whole) does not include a transformer.

[0072] Converter 202 can also (or alternatively) be configured to perform AC-DC conversion (e.g., a rectifier), DC-AC conversion, and / or AC-AC conversion (e.g., in combination with an AC-DC converter), such as for charging a DC energy source from an AC source. In some embodiments, such as for performing AC-AC conversion, converter 202 can include a transformer, either alone or in combination with one or more power semiconductors (e.g., switches, diodes, thyristors, and the like). In other embodiments, such as those where weight and cost are significant factors, converter 202 can be configured to perform the conversion using only power switches, power diodes, or other semiconductor devices and without a transformer.

[0073] The energy source 206 is preferably a robust energy storage device that can output direct current and have an energy density suitable for energy storage applications for electrically powered devices. The fuel cell can be a single fuel cell, multiple fuel cells connected in series or parallel, or a fuel cell module. Two or more energy sources can be included within each module, where the two or more sources can include two batteries of the same or different types, two capacitors of the same or different types, two fuel cells of the same or different types, one or more batteries combined with one or more capacitors and / or fuel cells, and one or more capacitors combined with one or more fuel cells.

[0074] The energy source 206 can be an electrochemical battery, such as a single battery cell, or multiple battery cells connected together in a battery module or array, or any combination thereof. Figures 4A-4D are schematic diagrams depicting exemplary embodiments of the energy source 206 configured as a single battery cell 402 (Figure 4A), a battery module with a series connection of multiple (e.g., four) cells 402 (Figure 4B), a battery module with a parallel connection of single cells 402 (Figure 4C), and a battery module with a parallel connection of tributaries each having multiple (e.g., two) cells 402 (Figure 4D). Examples of battery types are described elsewhere herein. Examples of battery types include solid-state batteries, liquid electrolyte-based batteries, liquid-phase batteries, and flow batteries, such as lithium (Li) metal batteries, Li-ion batteries, Li-air batteries, sodium-ion batteries, potassium-ion batteries, magnesium-ion batteries, alkaline batteries, nickel metal hydride batteries, nickel sulfate batteries, lead-acid batteries, zinc-air batteries, and others. Some examples of Li-ion battery types include lithium cobalt oxide (LCO), lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), lithium nickel cobalt aluminum oxide (NCA), and lithium titanate oxide (LTO).

[0075] Energy source 206 can also be a high-energy density (HED) capacitor, such as an ultracapacitor or supercapacitor. HED capacitors can be configured as double-layer capacitors (electrostatic charge storage), pseudocapacitors (electrochemical charge storage), hybrid capacitors (electrostatic and electrochemical), or others, as opposed to typical solid-dielectric-type electrolytic capacitors. In addition to higher capacitance, HED capacitors can have energy densities 10 to 100 times (or higher) than those of electrolytic capacitors. For example, HED capacitors can have specific energies greater than 1.0 watt-hours per kilogram (Wh / kg) and capacitances greater than 10 to 100 farads (F). Similar to the battery described with respect to FIGS. 4A-4D , energy source 206 can be configured as a single HED capacitor or multiple HED capacitors connected together in an array (e.g., in series, parallel, or a combination thereof).

[0076] Energy source 206 can also be a fuel cell. Examples of fuel cells include proton exchange membrane fuel cells (PEMFCs), phosphoric acid fuel cells (PAFCs), solid acid fuel cells, alkaline fuel cells, high-temperature fuel cells, solid oxide fuel cells, molten electrolyte fuel cells, and others. Similar to the batteries described with respect to Figures 4A-4D, energy source 206 can be configured as a single fuel cell or multiple fuel cells connected together in an array (e.g., in series, parallel, or a combination thereof). The foregoing examples of batteries, capacitors, and fuel cells are not intended to form an exhaustive list, and one of ordinary skill in the art will recognize other variations that fall within the scope of the present subject matter.

[0077] The energy buffer 204 is connected to a DC line or link (e.g., +V DC , as described below). L and -V DC L) to help maintain stability in the DC link voltage. These fluctuations may be relatively low (e.g., kilohertz) or high (e.g., megahertz) frequency fluctuations or harmonics caused by switching or other transients in converter 202. These fluctuations may be absorbed by buffer 204 instead of being passed to source 206 or ports IO3 and IO4 of converter 202.

[0078] The power connection 110 is a connection for transporting energy or power to, from, and through the module 108. The module 108 can output energy from an energy source 206 to the power connection 110, where it can be transported to other modules or loads in the system. The module 108 can also receive energy from other modules 108 or from charging sources (DC chargers, single-phase chargers, multi-phase chargers). Signals can also be passed through the module 108 and bypass the energy source 206. The flow of energy or power into and out of the module 108 is performed by the converter 202 under the control of the LCD 114 (or another entity in the system 102).

[0079] In the embodiment of Figure 2A, the LCD 114 is implemented as a component separate from the module 108 (e.g., not in a shared module housing) and is capable of connecting to and communicating with the converter 202 via a communication path 116. In the embodiment of Figure 2B, the LCD 114 is included as a component of the module 108 and is capable of connecting to and communicating with the converter 202 via an internal communication path 118 (e.g., a shared bus or a discrete connection). The LCD 114 may also be capable of receiving signals from and transmitting signals to the energy buffer 204 and / or the energy source 206 via paths 116 or 118.

[0080] The module 108 may also include monitor circuitry 208 configured to monitor (e.g., collect, sense, measure, and / or determine) one or more aspects of the module 108 and / or its components, such as voltage, current, temperature, or other operating parameters that constitute status information (or may be used to determine the status information, e.g., by the LCD 114). A primary function of the status information is to describe the state of one or more energy sources 206 of the module 108 and enable a determination regarding how much to utilize the energy source relative to other sources in the system 100, although status information describing the state of other components (e.g., voltage, temperature, and / or presence of a fault in the buffer 204, temperature and / or presence of a fault in the converter 202, presence of a fault anywhere in the module 108, etc.) may likewise be used in the utilization determination. The monitor circuitry 208 may include one or more sensors, shunts, dividers, fault detectors, coulomb counters, controllers, or other hardware and / or software configured to monitor such aspects. The monitor circuitry 208 can be separate from the various components 202, 204, and 206, or can be integrated with each component 202, 204, and 206 (as shown in FIGS. 2A-2B), or any combination thereof. In some embodiments, the monitor circuitry 208 can be part of or shared with a battery management system (BMS) for the battery energy source 204. Discrete circuitry is not required to monitor each type of status information, as more than one type of status information can be monitored using a single circuit or device or otherwise determined algorithmically without the need for additional circuitry.

[0081] The LCD 114 can receive status information (or raw data) about the module components via communication paths 116, 118. The LCD 114 can also transmit information to the module components via paths 116, 118. Paths 116 and 118 can include diagnostic, measurement, protection, and control signal lines. The transmitted information can be control signals for one or more module components. The control signals can be switch signals for the converter 202 and / or one or more signals requesting status information from the module components. For example, the LCD 114 can cause the status information to be transmitted via paths 116, 118 by directly requesting the status information or, in some cases, by applying a stimulus (e.g., a voltage) to generate the status information in combination with a switch signal that places the converter 202 in a particular state.

[0082] The physical configuration or layout of module 108 can take a variety of forms. In some embodiments, module 108 can include a common housing within which all module components, e.g., converter 202, buffer 204, and source 206, are housed along with other optional components, such as an integrated LCD 114. In other embodiments, the various components can be separated within discrete housings that are affixed together. FIG. 2C is a block diagram depicting an exemplary embodiment of module 108 having a first housing 220 that holds the module's energy source 206 and associated electronics, such as monitor circuitry 208 (not shown), a second housing 222 that holds module electronics, such as converter 202, energy buffer 204, and other associated electronics, such as monitor circuitry (not shown), and a third housing 224 that holds the LCD 114 (not shown) for module 108. Electrical connections between the various module components may pass through the housing 220 , 222 , 224 and may be exposed either on the housing exterior for connection to other devices such as other modules 108 or MCD 112 .

[0083] The modules 108 of system 100 can be physically arranged relative to each other in various configurations, depending on the needs of the application and the number of loads. For example, in a stationary application where system 100 provides power for a microgrid, the modules 108 can be installed in one or more racks or other frameworks. Such a configuration may also be suitable for larger mobile applications, such as marine vessels. Alternatively, the modules 108 can be affixed together and located in a common housing, referred to as a pack. The rack or pack may have its own dedicated cooling system shared across all modules. A pack configuration is useful for smaller mobile applications, such as electric vehicles. System 100 can be implemented using one or more racks (e.g., for parallel feeding into a microgrid), or one or more packs (e.g., feeding different motors in a vehicle), or a combination thereof. FIG. 2D is a block diagram depicting an example embodiment of system 100 in which nine modules 108 are configured as a pack, electrically and physically coupled together within a common housing 230.

[0084] Examples of these and further configurations are described in WO 2020 / 205574, which is incorporated herein by reference in its entirety for all purposes.

[0085] 3A-3C are block diagrams depicting example embodiments of module 108 having various electrical configurations. These embodiments are described as having one LCD 114 / module 108, with the LCD 114 housed within an associated module, but may be otherwise configured as described herein. FIG. 3A depicts a first example configuration of module 108A within system 100. Module 108A includes an energy source 206, an energy buffer 204, and a converter 202A. Each component has a power connection port (e.g., terminal, connector), referred to herein as an IO port, into which and / or from which power may be input. Such ports may also be referred to as input or output ports, depending on the context.

[0086] The energy source 206 can be configured as any of the energy source types described herein (e.g., a battery, HED capacitor, fuel cell, or others, as described with respect to FIGS. 4A-4D ). Ports IO1 and IO2 of the energy source 206 can be connected to ports IO1 and IO2, respectively, of the energy buffer 204. The energy buffer 204 can be configured to buffer or filter high and low frequency energy waves arriving at the buffer 204 through the converter 202, which may otherwise degrade the performance of the module 108. The topology and components for the buffer 204 are selected to accommodate the maximum allowable amplitude of these high frequency voltage waves. Several (non-exhaustive) example embodiments of the energy buffer 204 are depicted in the schematic diagrams of FIGS. 5A-5C . In FIG. 5A , the buffer 204 is configured with an electrolytic and / or film capacitor C EB 5B, the buffer 204 is connected to two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB25C, the buffer 204 is formed by two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB2 and diode D EB and a quasi-Z-source network 720 formed by

[0087] Ports IO3 and IO4 of energy buffer 204 can be connected to ports IO1 and IO2, respectively, of converter 202A, which can be configured as any of the power converter types described herein. FIG. 6A is a schematic diagram depicting an example embodiment of converter 202A configured as a DC-AC converter that can receive DC voltages at ports IO1 and IO2 and switch pulses to generate at ports IO3 and IO4. Converter 202A can include multiple switches, here converter 202A includes four switches S3, S4, S5, and S6 arranged in a full-bridge configuration. Control system 102 or LCD 114 can control each switch independently via control input line 118-3 to each gate.

[0088] The switches can be any suitable switch type, such as power semiconductors such as metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated-gate bipolar transistors (IGBTs), or gallium nitride (GaN) transistors, as shown here. The semiconductor switches can operate at relatively high switching frequencies, thereby allowing converter 202 to be operated in pulse-width modulation (PWM) mode, if desired, and respond to control commands within relatively short time intervals. This can provide high tolerance and fast dynamic behavior of output voltage regulation in transient mode.

[0089] In this embodiment, the DC line voltage V DC Lcan be applied to the converter 202 between ports IO1 and IO2. Different combinations of switches S3, S4, S5, and S6 allow for V DC L By connecting the GND to ports IO3 and IO4, converter 202 can provide three different voltage outputs: +V DC L , 0, and -V DC L can be generated at ports IO3 and IO4. The switch signal provided to each switch controls whether the switch is turned on (closed) or off (open). L To obtain a -V DC voltage, switches S3 and S6 are turned on while S4 and S5 are turned off. L can be obtained by turning on switches S4 and S5 and turning off S3 and S6. The output voltages can be set to zero (including near zero) or a reference voltage by turning S4 and S6 off with S3 and S5 on, or by turning S3 and S5 off with S4 and S6 on. These voltages can be output from the module 108 via the power connection 110. Ports IO3 and IO4 of the converter 202 can be connected to (or from) module IO ports 1 and 2 of the power connection 110 to generate output voltages for use with output voltages from other modules 108.

[0090] Control or switch signals for the embodiments of converter 202 described herein can be generated in different ways depending on the control technique utilized by system 100 to generate the output voltage of converter 202. In some embodiments, the control technique is a PWM technique, such as space vector pulse-width modulation (SVPWM) or sinusoidal pulse-width modulation (SPWM), or variations thereof. FIG. 8A is a voltage versus time graph depicting an example of an output voltage waveform 802 of converter 202. For ease of explanation, embodiments herein will be described in the context of a PWM control technique, although embodiments are not limited thereto. Other classes of techniques can also be used. One alternative class is based on hysteresis, examples of which are described in International Publication Nos. WO 2018 / 231810 A1, WO 2018 / 232403 A1, and WO 2019 / 183553 A1 (incorporated herein by reference for all purposes).

[0091] Each module 108 can be configured with multiple energy sources 206 (e.g., two, three, four, or more). Each energy source 206 of a module 108 can be controllable (switchable) to supply power to the connection 110 (or receive power from a charging source) independently of the other sources 206 of the module. For example, all sources 206 can output power to (or be charged with) the connection 110 simultaneously, or only one (or a subset) of the sources 206 can supply power (or be charged) at any one time. In some embodiments, the sources 206 of a module can exchange energy between themselves, e.g., one source 206 can charge another source 206. The sources 206 can each be configured as any energy source described herein (e.g., a battery, a HED capacitor, a fuel cell). The sources 206 can each be of the same type (e.g., each can be a battery) or different types (e.g., a first source can be a battery and a second source can be a HED capacitor, or a first source can be a battery having a first type (e.g., an NMC) and a second source can be a battery having a second type (e.g., an LFP).

[0092] 3B is a block diagram depicting an example embodiment of module 108B in a dual energy source configuration with a primary energy source 206A and a secondary energy source 206B. Ports IO1 and IO2 of primary source 202A can be connected to ports IO1 and IO2 of energy buffer 204. Module 108B includes converter 202B with an additional IO port. Ports IO3 and IO4 of buffer 204 can be connected to ports IO1 and IO2, respectively, of converter 202B. Ports IO1 and IO2 of secondary source 206B can be connected to ports IO5 and IO2, respectively, of converter 202B (and also connected to port IO4 of buffer 204).

[0093] In this exemplary embodiment of module 108B, primary energy source 202A, along with the other modules 108 of system 100, supplies the average power required by the load. Secondary source 202B can perform the function of an auxiliary energy source 202 by providing additional power at load power peaks, absorbing excess power, or otherwise.

[0094] As mentioned, both the primary source 206A and the secondary source 206B can be utilized simultaneously or at separate times depending on the switch state of the converter 202B. If simultaneously, the electrolytic and / or film capacitors (C ES ) can be placed in parallel with source 206B and act as an energy buffer for source 206B, as depicted in FIG. 4E, or energy source 206B can be configured to utilize a HED capacitor in parallel with another energy source (e.g., a battery or fuel cell), as depicted in FIG. 4F.

[0095] 6B and 6C are schematic diagrams depicting exemplary embodiments of converters 202B and 202C, respectively. Converter 202B includes switch network portions 601 and 602A. Portion 601, in a similar manner to converter 202A, is configured as a full bridge and includes switches S3-S6 configured to selectively couple IO1 and IO2 to either IO3 or IO4, thereby varying the output voltage of module 108B. Portion 602A is configured as a half bridge and includes switches S1 and S2 coupled between ports IO1 and IO2. A coupled inductor L C However, switch portion 602A is connected between port IO5 and node 1, which exists between switches S1 and S2, so that it is a bidirectional converter that can regulate (boost or buck) voltage (or conversely, current). Switch portion 602A is connected between port IO5 and node 1, which exists between switches S1 and S2, so that it is at a voltage that is effectively zero potential, +V DC, referenced to port IO2. L2Two different voltages can be generated at node 1, ie, 0 and 0. The current drawn from or input to energy source 202B can be controlled by using, for example, pulse width modulation techniques or hysteretic control methods to commutate switches S1 and S2 through coupled inductor L. C The voltage applied to the output of the power supply can be controlled by adjusting the voltage on the output of the power supply. Other techniques can also be used.

[0096] Converter 202C differs from that of 202B because switch portion 602B includes switches S1 and S2 configured as a half-bridge and coupled between ports IO5 and IO2. C However, switch portion 602B is connected between port IO1 and node 1, which exists between switches S1 and S2, so as to be configured to regulate the voltage.

[0097] Control system 102 or LCD 114 can independently control each switch of converters 202B and 202C via control input line 118-3 to each gate. In these embodiments and that of FIG. 6A, LCD 114 (rather than MCD 112) generates the switching signals for the converter switches. Alternatively, MCD 112 can also generate the switching signals, which can be communicated directly to the switches or relayed by LCD 114.

[0098] In embodiments in which module 108 includes three or more energy sources 206, converters 202B and 202C can be scaled accordingly, such that each additional energy source 206B is coupled to an additional IO port that leads to an additional switch network portion 602A or 602B, depending on the needs of the particular source. For example, dual source converter 202 can include both switch portions 202A and 202B.

[0099] A module 108 with multiple energy sources 206 can perform additional functions such as energy sharing between sources 206, energy capture from within the application (e.g., regenerative braking), charging a primary source with a secondary source even while the overall system is in a discharge state, and active filtering of the module output. Active filtering functions can also be performed by the module, with a typical electrolytic capacitor instead of a secondary energy source. Examples of these functions are described in further detail in International Publication No. WO 2020 / 205574, filed March 27, 2020, and entitled "Module-Based Energy Systems Capable Of Cascaded And Interconnected Configurations, And Methods Related Thereto," and International Publication No. WO 2019 / 183553, filed March 22, 2019, and entitled "Systems and Methods for Power Management and Control," both of which are incorporated herein by reference in their entirety for all purposes.

[0100] Each module 108 can be configured to supply one or more auxiliary loads using its one or more energy sources 206. An auxiliary load is a load that requires a lower voltage than the primary load 101. Examples of an auxiliary load can be, for example, the on-board electrical network of an electric vehicle or the HVAC system of an electric vehicle. A load of the system 100 can be, for example, an electric vehicle motor or one of the phases of an electrical grid. This embodiment can allow for a complete decoupling between the electrical characteristics of the energy source (terminal voltage and current) and the electrical characteristics of the load.

[0101] 3C is a block diagram depicting an exemplary embodiment of module 108C configured to supply power to first and second auxiliary loads 301 and 302. Module 108C includes energy source 206, energy buffer 204, and converter 202B coupled together in a manner similar to that of FIG. 3B. First auxiliary load 301 requires a voltage comparable to that supplied by source 206. Load 301 is coupled to IO ports 3 and 4 of module 108C, which are in turn coupled to ports IO1 and IO2 of source 206. Source 206 can output power to both power connection 110 and load 301. Second auxiliary load 302 requires a constant voltage lower than that of source 206. Load 302 is coupled to IO ports 5 and 6 of module 108C, which are coupled to ports IO5 and IO2, respectively, of converter 202B. Converter 202B includes a coupled inductor L coupled to port IO5 (FIG. 6B). C The energy provided by the source 206 can be supplied to the load 302 through the switch portion 602 of the converter 202B. The load 302 has an input capacitor (a capacitor can be added to the module 108C if not applicable), and therefore the switches S1 and S2 are connected to the coupled inductor L C It is assumed that the voltage at source 206 is rectified to regulate the voltage above and the current through it, thus producing a stable constant voltage for load 302. This regulation allows the voltage of source 206 to be stepped down to a lower magnitude voltage required by load 302.

[0102] Module 108C can thus be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, with one or more first loads coupled to IO ports 3 and 4. Module 108C can also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302. If multiple second auxiliary loads 302 are present, then for each additional load 302, module 108C can be scaled with additional dedicated module output ports (such as 5 and 6), additional dedicated switch sections 602, and additional converter IO ports coupled to the additional sections 602.

[0103] Energy source 206 can therefore supply power for any number of auxiliary loads (e.g., 301 and 302) as well as a corresponding portion of the system output power required by primary load 101. The power flow from source 206 to the various loads can be adjusted as desired.

[0104] The module 108 can be configured to supply the first and / or second auxiliary loads (FIG. 3C) using two or more energy sources 206 (FIG. 3B) as needed, through the addition of switch portion 602 and converter port IO5 for each additional source 206B or second auxiliary load 302. Additional module IO ports (e.g., 3, 4, 5, 6) can be added as needed. The module 108 can also be configured as an interconnection module to exchange energy (e.g., for balancing) between two or more arrays, two or more packs, or two or more systems 100 as described further herein. This interconnection functionality can likewise be combined with multiple source and / or multiple auxiliary load supply capabilities.

[0105] The control system 102 may perform various functions for the components of the modules 108A, 108B, and 108C. These functions may include managing the utilization (amount of usage) of each energy source 206, protecting the energy buffer 204 from overcurrent, overvoltage, and high temperature conditions, and controlling and protecting the converter 202.

[0106] For example, LCD 114 may receive one or more monitored voltages, temperatures, and currents from each energy source 206 (or monitor circuitry) to manage (e.g., adjust by increasing, decreasing, or maintaining) the utilization of each energy source 206. The monitored voltages may be at least one, and preferably all, of the voltage of each basic component independent of the other components of source 206 (e.g., each individual battery cell, HED capacitor, and / or fuel cell), or the voltage of the group of basic components as a whole (e.g., the voltage of the battery array, HED capacitor array, and / or fuel cell array). Similarly, the monitored temperatures and currents may be at least one, and preferably all, of the temperature and current of each basic component independent of the other components of source 206, or the temperature and current of the group of basic components as a whole, or any combination thereof. The monitored signals may be status information with which LCD 114 may perform one or more of the following: calculate or determine the actual capacity, actual state of charge (SOC), and / or state of health (SOH) of a basic component or group of basic components, set or output a warning or alarm indication based on the monitored and / or calculated status information, and / or transmit status information to MCD 112. LCD 114 may receive control information (e.g., modulation index, synchronization signal) from MCD 112 and use this control information to generate switch signals for converter 202 that manage utilization of source 206.

[0107] To protect the energy buffer 204, the LCD 114 may receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or monitor circuitry). The monitored voltages may be monitored for each basic component (e.g., C EB , C EB1 , C EB2 , L EB1 , L EB2 , D EB ) or the voltage of the group of basic components of buffer 204 as a whole (e.g., between IO1 and IO2 or between IO3 and IO4). Similarly, the monitored temperatures and currents can be at least one, preferably all, of the temperature and current of each basic component of buffer 204 independent of the other components, or the temperature and current of the group of basic components of buffer 204 as a whole, or any combination thereof. The monitored signals can be status information with which LCD 114 can perform one or more of the following: set or output a warning or alarm indication, communicate status information to MCD 112, or control converter 202 can adjust (increase or decrease) the utilization of source 206 and module 108 as a whole for buffer protection.

[0108] To control and protect converter 202, LCD 114 can receive control information (e.g., a modulated reference signal, or a reference signal and a modulation index) from MCD 112, which can be used within LCD 114 to generate control signals for each switch (e.g., S1-S6) using PWM techniques. LCD 114 can receive current feedback signals from current sensors in converter 202, which can be used for overcurrent protection, along with one or more fault status signals from the converter switch driver circuits (not shown), which can convey information about the fault status (e.g., short-circuit or open-circuit failure mode) of all switches in converter 202. Based on this data, LCD 114 can manage module 108 utilization and potentially make decisions regarding the combination of switching signals to be applied to bypass or disconnect converter 202 (and module 108 entirely) from system 100.

[0109] When controlling module 108C, which supplies second auxiliary load 302, LCD 114 displays one or more monitored voltages within module 108C (e.g., the voltage between IO ports 5 and 6) and one or more monitored currents (e.g., the current of load 302, the voltage across coupled inductor L C Based on these signals, the LCD 114 can adjust the switching cycles of S1 and S2 to control (and stabilize) the voltage to the load 302 (e.g., by adjusting the modulation index or reference waveform). Example of a cascaded energy system topology

[0110] Two or more modules 108 can be coupled together in a cascaded array that outputs a voltage signal formed by the superposition of discrete voltages generated by each module 108 in the array. FIG. 7A is a block diagram depicting an exemplary embodiment of a topology for system 100, in which N modules 108-1, 108-2...108-N are coupled together in series to form a series array 700. In this and all embodiments described herein, N can be any integer greater than 1. Array 700 includes a first system IO port SI01 and a second system IO port SI02, across which the array output voltage is generated. Array 700 can be used as a DC or single-phase AC energy source for DC or AC single-phase loads that may be connected to SI01 and SI02 of array 700. FIG. 8A is a voltage versus time plot depicting an exemplary output signal produced by a single module 108 with a 48-volt energy source. FIG. 8B is a voltage versus time plot depicting an exemplary single-phase AC output signal generated by an array 700 having six 48V modules 108 coupled in series.

[0111] System 100 can be arranged in a variety of different topologies to meet the varying needs of an application. System 100 can provide multi-phase power (e.g., 2-phase, 3-phase, 4-phase, 5-phase, 6-phase, etc.) to a load through the use of multiple arrays 700, with each array generating an AC output signal having a different phase angle.

[0112] FIG. 7B is a block diagram depicting system 100 with two arrays 700-PA and 700-PB coupled together. Each array 700 is one-dimensional and formed by a series connection of N modules 108. The two arrays 700-PA and 700-PB can each generate a single-phase AC signal, with the two AC signals having different phase angles PA and PB (e.g., 180 degrees apart). IO port 1 of module 108-1 of each array 700-PA and 700-PB can form or be connected to system IO ports SIO1 and SIO2, respectively, which can then serve as the first output of each array, which can provide two-phase power to a load (not shown). Alternatively, ports SIO1 and SIO2 can be connected to provide single-phase power from the two parallel arrays. IO port 2 of module 108-N of each array 700-PA and 700-PB, on the opposite end of the array from system IO ports SIO1 and SIO2, can serve as a second output for each array 700-PA and 700-PB, and can be coupled together at a common node that can optionally be used, as desired, for an additional system IO port SIO3, which can serve as a neutral terminal. This common node can be referred to as a rail, and IO port 2 of module 108-N of each array 700 can be referred to as being on the rail side of the array.

[0113] 7C is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together. Each array 700 is one-dimensional and formed by a series connection of N modules 108. Each of the three arrays 700-1 and 700-2 can generate a single-phase AC signal, with the three AC signals having different phase angles PA, PB, and PC (e.g., spaced 120 degrees apart). IO port 1 of module 108-1 of each array 700-PA, 700-PB, and 700-PC can form or be connected to system IO ports SIO1, SIO2, and SIO3, respectively, which can in turn provide three-phase power to a load (not shown). The IO ports 2 of modules 108-N of each array 700-PA, 700-PB, and 700-PC can be coupled together at a common node, which can optionally be used, as desired, for an additional system IO port SIO4, which serves as a neutral terminal.

[0114] 7B and 7C can be extended to systems 100 that generate power in even more phases. For example, a non-exhaustive list of additional examples includes a system 100 having four arrays 700 configured to generate single-phase AC signals, each having a different phase angle (e.g., 90 degrees apart), a system 100 having five arrays 700 configured to generate single-phase AC signals, each having a different phase angle (e.g., 72 degrees apart), and a system 100 having six arrays 700, each configured to generate single-phase AC signals, each having a different phase angle (e.g., 60 degrees apart).

[0115] System 100 can be configured such that arrays 700 are interconnected at electrical nodes between modules 108 within each array. Figure 7D is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. Each array 700 includes a first series connection of M modules 108 (M is two or more) coupled with a second series connection of N modules 108 (N is two or more). The delta configuration is formed by the interconnections between the arrays, which can be placed in any desired location. In this embodiment, IO port 2 of module 108-(M+N) of array 700-PC is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PA, IO port 2 of module 108-(M+N) of array 700-PB is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PC, and IO port 2 of module 108-(M+N) of array 700-PA is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PB.

[0116] FIG. 7E is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. This embodiment is similar to that of FIG. 7D but with a different cross-connection. In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled to IO port 1 of module 108-1 of array 700-PA, IO port 2 of module 108-M of array 700-PB is coupled to IO port 1 of module 108-1 of array 700-PC, and IO port 2 of module 108-M of array 700-PA is coupled to IO port 1 of module 108-1 of array 700-PB. The arrangements of FIGS. 7D and 7E can be implemented with as few as two modules in each array 700. The combined delta and series configuration allows for an effective exchange of energy between all modules 108 of the system (phase-to-phase balance) and the phases of the grid or load, and also allows for a reduction in the total number of modules 108 in the array 700 to obtain the desired output voltage.

[0117] In the embodiments described herein, it is advantageous for the number of modules 108 to be the same in each array 700 in the system 100, but that is not required, and different arrays 700 can have different numbers of modules 108. Furthermore, each array 700 can have modules 108 that are all of the same configuration (e.g., all modules are 108A, all modules are 108B, all modules are 108C, etc.) or that are of different configurations (e.g., one or more modules are 108A, one or more modules are 108B, one or more modules are 108C, etc.). Accordingly, the range of topologies of the system 100 covered herein is broad. Exemplary Embodiments of Control Methodology

[0118] As mentioned, control of the system 100 can be implemented according to various methodologies, such as hysteresis or PWM. Some examples of PWM include space vector modulation and sinusoidal pulse width modulation, where the switching signals for the converter 202 are generated using a phase shifted carrier technique that continuously rotates the utilization of each module 108, distributing power equally among them.

[0119] 8C-8F are plots depicting an exemplary embodiment of a phase-shifted PWM control methodology that can generate multi-level output PWM waveforms using gradually shifted two-level waveforms. An X-level PWM waveform can be generated by summing (X-1) / 2 two-level PWM waveforms. These two-level waveforms can be generated by comparing a reference waveform Vref with a carrier wave that is gradually shifted by 360° / (X-1). The carrier wave is triangular, but the embodiment is not so limited. A nine-level example is shown in FIG. 8C (using four modules 108). The carrier wave is gradually shifted by 360° / (9-1)=45° and compared to Vref. The resulting two-level PWM waveform is shown in FIG. 8E. These two-level waveforms may be used as switching signals for the semiconductor switches (e.g., S1-S6) of the converter 202. As an example, referring to FIG. 8E, for a one-dimensional array 700 including four modules 108, each with a converter 202, the 0° signal is for control of S3 of the first module 108-1, the 180° signal is for S6, the 45° signal is for S3 and the 225° signal is for S6 of the second module 108-2, the 90° signal is for S3 of the third module 108-3, the 270° signal is for S6, the 135° signal is for S3 of the fourth module 108-4, and the 315° signal is for S6. The signal for S3 is complementary to S4, with sufficient dead time to avoid shoot-through of each half-bridge, and the signal for S5 is complementary to S6. FIG. 8F depicts an exemplary single-phase AC waveform produced by the superposition (summation) of the output voltages from the four modules 108.

[0120] An alternative is to utilize both positive and negative reference signals along with the first (N-1) / 2 carrier. A nine-level embodiment is shown in FIG. 8D. In this embodiment, the 0° to 135° switching signal (FIG. 8E) is generated by comparing +Vref to the 0° to 135° carrier of FIG. 8D, and the 180° to 315° switching signal is generated by comparing -Vref to the 0° to 135° carrier of FIG. 8D. However, the comparison logic in the latter case is reversed. Other techniques, such as a state machine decoder, may also be used to generate the gate signals for the switches of converter 202.

[0121] In multi-phase system embodiments, the same carrier wave can be used for each phase, or the set of carrier waves can be shifted as a whole for each phase. For example, in a three-phase system with a single reference voltage (Vref), each array 700 can use the same number of carrier waves with the same relative offsets as shown in FIGS. 8C and 8D, but the carrier wave of the second phase is shifted 120 degrees compared to the carrier wave of the first phase, and the carrier wave of the third phase is shifted 240 degrees compared to the carrier wave of the first phase. If different reference voltages are available for each phase, phase information can be carried within the reference voltage, and the same carrier wave can be used for each phase. While in many cases the carrier frequency will be fixed, in some exemplary embodiments the carrier frequency can be adjusted, which can help reduce losses in the EV motor under high current conditions.

[0122] An appropriate switching signal can be provided to each module by the control system 102. For example, the MCD 112 can provide Vref and an appropriate carrier signal to each LCD 114 depending on the module or modules 108 that the LCD 114 controls, and the LCD 114 can then generate the switching signal. Alternatively, all LCDs 114 in the array can provide all carrier signals, and the LCD can select the appropriate carrier signal.

[0123] The relative utilization of each module 108 may be adjusted based on the status information, as described herein, to implement one or more parameter balancing. Parameter balancing may involve adjusting utilization to minimize parameter divergence over time compared to a system in which individual module utilization adjustments are not implemented. Utilization may be the relative amount of time a module 108 is discharging when the system 100 is in a discharging state, or the relative amount of time a module 108 is charging when the system 100 is in a charging state.

[0124] As described herein, modules 108 can be balanced relative to other modules in an array 700, which may be referred to as intra-array or intra-phase balancing, and different arrays 700 can also be balanced relative to each other, which may be referred to as inter-array or inter-phase balancing. Arrays 700 of different subsystems can also be balanced relative to each other. The control system 102 can simultaneously perform any combination of intra-phase balancing, inter-phase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

[0125] 9A is a block diagram depicting an example embodiment of an array controller 900 of the control system 102 for a single-phase AC or DC array. The array controller 900 may include a peak detector 902, a divider 904, and an intra-phase (or intra-array) balance controller 906. The array controller 900 may receive as inputs a reference voltage waveform (Vr) and status information (e.g., state of charge (SOCi), temperature (Ti), capacity (Qi), and voltage (Vi)) for each of the N modules 108 in the array and generate as outputs a normalized reference voltage waveform (Vrn) and a modulation index (Mi). The peak detector 902 detects the peak (Vpk) of Vr, which may be specific to the phase on which the controller 900 is operating and / or balancing. The divider 904 generates Vrn by dividing Vr by the detected Vpk. The intra-phase balance controller 906 uses Vpk along with status information (eg, SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module 108 in the array 700 being controlled.

[0126] The modulation index and Vrn can be used to generate a switching signal for each converter 202. The modulation index can be a number between zero and one (inclusive). For a particular module 108, a normalized reference Vrn can be modulated or scaled by Mi, and this modulated reference signal (Vrnm) can be used as Vref (or -Vref) according to the PWM techniques described with respect to FIGS. 8C-8F or other techniques. In this manner, the modulation index can be used to control the PWM switching signals provided to the converter switching circuitry (e.g., S3-S6 or S1-S6) and thus regulate the operation of each module 108. For example, a module 108 controlled to maintain normal or full operation may receive a Mi of one, while a module 108 controlled to operate less than normal or full may receive a Mi of less than one, and a module 108 controlled to cease power output may receive a Mi of zero. This operation can be performed in a variety of ways by the control system 102, such as by the MCD 112 outputting Vrn and Mi to the appropriate LCD 114 for modulation and switch signal generation, by the MCD 112 performing the modulation and outputting the modulated Vrnm to the appropriate LCD 114 for switch signal generation, or by the MCD 112 performing the modulation and switch signal generation and outputting the switch signal directly to the LCD or converter 202 of each module 108. Vrn can be transmitted continuously, with Mi transmitted at regular intervals, such as once per period of Vrn or once per minute.

[0127] The controller 906 can generate Mi for each module 108 using any type or combination of types of status information described herein (e.g., SOC, temperature (T), Q, SOH, voltage, current). For example, using SOC and T, a module 108 can have a relatively high Mi if its SOC is relatively high and its temperature is relatively low compared to other modules 108 in the array 700. If either of the SOCs is relatively low or T is relatively high, that module 108 can have a relatively low Mi and result in less utilization than other modules 108 in the array 700. The controller 906 can determine Mi such that the sum of the module voltages does not exceed Vpk. For example, Vpk is the sum of the products of the voltages of each module's sources 206 and the Mi for that module (e.g., Vpk=M1V1+M2V2+M3V3...+M N V N etc.) Different combinations of modulation indexes, and therefore individual voltage contributions by the modules, may be used, but the total generated voltage should remain the same.

[0128] The controller 900 can control operation so that the SOC of the energy sources within each module remains balanced or, if unbalanced, converges to a balanced condition, and / or the temperature of the energy sources or other components (e.g., energy buffers) within each module 108 remains balanced or, if unbalanced, converges to a balanced condition, as long as it does not prevent the system from achieving its power output requirements at any time (e.g., during maximum acceleration of an EV). Power flow into and out of modules can be adjusted so that capacitance differences between sources do not cause SOC deviations. SOC and temperature balancing can indirectly cause some balancing of SOH. While voltage and current can be balanced directly if desired, in many embodiments, the primary goal of the system is to balance SOC and temperature, and SOC balancing can lead to voltage and current balancing in a highly symmetrical system where modules are of similar capacitance and impedance.

[0129] Since balancing all parameters may not be possible simultaneously (e.g., balancing one parameter may further unbalance another), a combination of balancing any two or more parameters (SOC, T, Q, SOH, V, I) may be applied, with priority given to one or the other, depending on the requirements of the application. Priority in balancing may be given to SOC over the other parameters (T, Q, SOH, V, I), with exceptions being allowed if one of the other parameters (T, Q, SOH, V, I) reaches a significant imbalance condition outside the threshold.

[0130] Balancing between arrays 700 of different phases (or arrays of the same phase, e.g., if parallel arrays are used) can be performed in parallel with intra-phase balancing. FIG. 9B depicts an exemplary embodiment of an Ω-phase (or Ω-array) controller 950 configured for operation in an Ω-phase system 100 having at least Ω arrays 700, where Ω is any integer greater than 1. The controller 950 may include one inter-phase (or inter-array) controller 910, Ω intra-phase balance controllers 906-PA...906-PΩ for phases PA-PΩ, and a peak detector 902 and divider 904 ( FIG. 9A ) for generating a normalized reference VrnPA-VrnPΩ from each phase-specific reference VrPA-VrPΩ. The intra-phase controller 906 may generate Mi for each module 108 of each array 700, as described with respect to FIG. 9A . The phase-to-phase balance controller 910 is configured or programmed to balance the sides of the modules 108 across the entire multidimensional system, for example, between arrays of different phases. This may be achieved through injecting a common mode into the phases (e.g., neutral terminal point shift), or through the use of interconnection modules (described herein), or both. Common mode injection involves introducing a phase and amplitude shift into the reference signal VrPA-VrPΩ to generate a normalized waveform VrnPA-VrnPΩ, compensating for imbalances within one or more arrays, and is further described in International Publication No. WO 2020 / 205574, which is incorporated herein.

[0131] Controllers 900 and 950 (and balance controllers 906 and 910) can be implemented in hardware, software, or a combination thereof within control system 102. Controllers 900 and 950 can be implemented within MCD 112, partially or completely distributed among LCD 114, or may be implemented as discrete controllers independent of MCD 112 and LCD 114. Exemplary Embodiments of an Interconnect (IC) Module

[0132] A module 108 can be connected between modules of different arrays 700 to exchange energy between arrays, act as a source for auxiliary loads, or both. Such a module is referred to herein as an interconnect (IC) module 108. The IC module 108 can be implemented in any of the module configurations already described (108A, 108B, 108C) and others to be described herein. The IC module 108 can include any number of one or more energy sources, an optional energy buffer, switch circuitry for supplying energy to one or more arrays and / or power to one or more auxiliary loads, control circuitry (e.g., a local control device), and monitor circuitry for collecting status information about the IC module itself or its various loads (e.g., SOC of the energy source, temperature of the energy source or energy buffer, capacity of the energy source, SOH of the energy source, voltage and / or current measurements for the IC module, voltage and / or current measurements for the auxiliary loads, etc.).

[0133] 10A is a block diagram depicting an example embodiment of system 100 capable of producing Ω-phase power using Ω arrays 700-PA-700-PΩ, where Ω can be any integer greater than 1. In this and other embodiments, IC module 108IC can be located on the rail side of array 700 such that the array 700 to which module 108IC is connected (in this embodiment, array 700-PA-700-PΩ) is electrically connected between module 108IC and the output to the load (e.g., SIO1-SIOΩ). Here, module 108IC has Ω IO ports for connection to IO port 2 of each module 108-N of array 700-PA-700-PΩ. In the configuration depicted here, module 108IC can perform phase balancing by selectively connecting one or more energy sources of module 108IC to one or more of array 700-PA-700-PΩ (or to no output, or equally to all outputs, if phase balancing is not required). System 100 can be controlled by control system 102 (not shown, see FIG. 1A).

[0134] FIG. 10B is a schematic diagram depicting an exemplary embodiment of module 108IC. In this embodiment, module 108IC includes energy source 206 connected to energy buffer 204, which in turn is connected to switch network 603. Switch network 603 may include switch network units 604-PA-604-PΩ to independently connect energy source 206 to each of arrays 700-PA-700-PΩ. Various switch configurations can be used for each unit 604, which in this embodiment is configured as a half-bridge with two semiconductor switches S7 and S8. Each half-bridge is controlled by control line 118-3 from LCD 114. This configuration is similar to module 108A described with reference to FIG. 3A. As described with reference to converter 202, switch network 603 can be configured with any switch type (e.g., MOSFET, IGBT, silicon, GaN, etc.) in any arrangement suitable for the application requirements.

[0135] The switch network unit 604 is coupled between the positive and negative terminals of the energy source 206 and has an output connected to an IO port of the module 108 IC. The unit 604-PA-604-PΩ is connected by the control system 102 to a voltage +V IC or -V ICto individual module I / O ports 1-Ω. The control system 102 can control the switch circuitry 603 according to any desired control technique, including the PWM and hysteresis techniques described herein. Here, the control circuitry 102 is implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 can receive monitoring data or status information from the monitor circuitry of the module 108 IC. This monitoring data and / or other status information derived from this monitoring data can be output to the MCD 112 for use in system control, as described herein. The LCD 114 can also receive timing information (not shown) for purposes of synchronization of the modules 108 of the system 100 and one or more carrier signals (not shown), such as sawtooth signals (FIGS. 8C-8D) used in PWM.

[0136] Due to phase-to-phase balance, relatively more energy from source 206 can be supplied to any one or more of arrays 700-PA-700-PΩ that are at a relatively low state of charge compared to the other arrays 700. This complementary energy supply to a particular array 700 allows the energy output of those cascaded modules 108-1-108-N within that array 700 to be reduced relative to the unsupplied phase arrays.

[0137] For example, in some exemplary embodiments applying PWM, the LCD 114 can be configured to receive (from the MCD 112) a normalized voltage reference signal (Vrn) for each of the one or more arrays 700 to which its module 108 IC is coupled, e.g., VrnPA-VrnPΩ. The LCD 114 can also receive modulation indexes MiPA-MiPΩ for switch units 604-PA-604-PΩ from the MCD 112, respectively, for each array 700. The LCD 114 can modulate (e.g., multiply) each individual Vrn with the modulation index (e.g., VrnA is multiplied by MiA) for the switch section directly coupled to that array and then utilize a carrier signal to generate a control signal for each switch unit 604. In other embodiments, the MCD 112 can perform the modulation and output a modulated voltage reference waveform for each unit 604 directly to the LCD 114 of the module 108 IC. In yet other embodiments, all processing and modulation may occur by a single control entity, which may output control signals directly to each unit 604 .

[0138] This switching can be modulated so that power from the energy source 206 can be supplied to the array 700 at appropriate intervals and durations. Such a methodology can be implemented in a variety of ways.

[0139] Based on collected status information about the system 100, such as the current capacity (Q) and SOC of each energy source in each array, the MCD 112 can determine the total charge for each array 700 (e.g., the total charge for an array can be determined as the sum of the capacities times the SOCs for each module in that array). The MCD 112 can determine whether a balanced or unbalanced condition exists (e.g., through the use of relative difference thresholds and other metrics described herein) and, as appropriate, generate modulation indices MiPA-MiPΩ for each switch unit 604-PA-604-PΩ.

[0140] During balanced operation, Mi per switch unit 604 can be set to a value that causes the same or similar amount of net energy to be supplied by the energy source 206 and / or energy buffer 204 to each array 700 over time. For example, Mi per switch unit 604 can be the same or similar and can be set to a level or value that causes the module 108IC to perform a net or time-averaged discharge of energy into one or more arrays 700-PA-700-PΩ during balanced operation, such that the module 108IC drains at the same rate as the other modules 108 in the system 100. In some embodiments, Mi per unit 604 can be set to a level or value that causes no net or time-averaged discharge of energy (causing a net energy discharge of zero) during balanced operation. This can be useful if the module 108IC has a lower total charge than the other modules in the system.

[0141] If an unbalanced condition occurs between arrays 700, the modulation index of system 100 can be adjusted to cause convergence toward a balanced condition or minimize further divergence. For example, control system 102 can cause module 108 to discharge more into an array 700 with a lower charge than the others, and cause modules 108-1-108-N of that lower array 700 to discharge relatively less (e.g., on a time-averaged basis). The relative net energy contributed by module 108 increases compared to modules 108-1-108-N of the supported array 700 and compared to the amount of net energy the other arrays contribute to module 108. This can be accomplished by increasing Mi for the switch unit 604 feeding that low array 700, and by decreasing the modulation indexes of the modules 108-1-108-N of the low array 700 in a manner that maintains Vout for that low array at an appropriate or required level and keeps the modulation indexes for the other switch units 604 feeding other higher arrays relatively unchanged (or decreases them).

[0142] 10A-10B can be used alone to provide phase-to-phase or array-to-array balancing for a single system, or can be used in combination with one or more other modules 108IC, each having an energy source and one or more switch portions 604 coupled to one or more arrays. For example, a module 108IC with Ω switch portions 604 coupled to Ω different arrays 700 can be combined with a second module 108IC having one switch portion 604 coupled to one array 700, such that the two modules are combined to feed a system 100 having Ω+1 arrays 700. Any number of modules 108IC can be combined in this manner, each coupled to one or more arrays of the system 100.

[0143] Additionally, the IC module can be configured to exchange energy between two or more subsystems of system 100. FIG. 10C is a block diagram depicting an example embodiment of system 100 with a first subsystem 1000-1 and a second subsystem 1000-2 interconnected by an IC module. Specifically, subsystem 1000-1 is configured to supply three-phase power PA, PB, and PC to a first load (not shown) using system I / O ports SIO1, SIO2, and SIO3, while subsystem 1000-2 is configured to supply three-phase power PD, PE, and PF to a second load (not shown) using system I / O ports SIO4, SIO5, and SIO6, respectively. For example, subsystems 1000-1 and 1000-2 can be configured as different packs supplying power for different motors of an EV or as different racks supplying power for different microgrids.

[0144] In this embodiment, each module 108IC is coupled to the first subsystem array 1000-1 (via IO port 1) and the first subsystem array 1000-2 (via IO port 2), and each module 108IC can be electrically connected to each other module 108IC using I / O ports 3 and 4, which are coupled to the energy source 206 of each module 108IC, as described with respect to module 108C in FIG. 3C. This connection places the sources 206 of modules 108IC-1, 108IC-2, and 108IC-3 in parallel; thus, the energy stored and supplied by the modules 108IC is pooled together by this parallel arrangement. Other arrangements, such as a serial connection, can also be used. The modules 108IC are housed within the common enclosure of subsystem 1000-1; however, the interconnection module can be external to the common enclosure and physically located as an independent entity between the common enclosures of both subsystems 1000-1.

[0145] Each module 108IC has a switch unit 604-1 coupled to IO port 1 and a switch unit 604-2 coupled to I / O port 2, as described with respect to FIG. 10B . Thus, for balancing between subsystems 1000 (e.g., pack-to-pack or rack-to-rack balancing), a particular module 108IC can supply relatively more energy to one or both of the two arrays to which it is connected (e.g., module 108IC-1 can supply array 700-PA and / or array 700-PD). Control circuitry can monitor relative parameters (e.g., SOC and temperature) of the arrays of different subsystems and adjust the energy output of the IC modules to compensate for imbalances between arrays or phases of different subsystems, in a manner similar to compensating for imbalances between two arrays of the same rack or pack as described herein. Because all three modules 108IC are in parallel, energy can be efficiently exchanged between every array of system 100. In this embodiment, each module 108 IC supplies two arrays 700, although other configurations can be used, including a single IC module for all arrays in system 100 and a configuration with one dedicated IC module per array 700 (e.g., six IC modules for six arrays, each IC module having one switch unit 604). In all cases, with multiple IC modules, energy sources can be coupled together in parallel to share energy as described herein.

[0146] In systems with IC modules between the phases, phase-to-phase balancing can also be performed by neutral terminal point shifting (or common-mode injection), as described above. Such a combination allows for more robust and flexible balancing under a wider range of operating conditions. System 100 can determine appropriate situations under which phase-to-phase balancing should be performed using neutral terminal point shifting alone, phase-to-phase energy injection alone, or a combination of both simultaneously.

[0147] The IC modules can also be configured to supply power to one or more auxiliary loads 301 (at the same voltage as source 206) and / or one or more auxiliary loads 302 (at a stepped-down voltage from source 302). FIG. 10D is a block diagram depicting an example embodiment of a three-phase system 100A with two modules 108IC connected to perform phase-to-phase balancing and supply auxiliary loads 301 and 302. FIG. 10E is a schematic diagram depicting this example embodiment of system 100, with emphasis placed on modules 108IC-1 and 108IC-2. Here, control circuitry 102 is again implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 receives monitoring data (e.g., SOC of ES1, temperature of ES1, Q of ES1, voltage of auxiliary loads 301 and 302, etc.) from module 108IC and can output this and / or other monitoring data to MCD 112 for use in system control, as described herein. Each module 108IC can include a switch portion 602A (or 602B, as described with respect to FIG. 6C ) for each load 302 being supplied by that module, and each switch portion 602 can be controlled by LCD 114, either independently or based on a control input from MCD 112, to maintain the required voltage level for the load 302. In this embodiment, each module 108IC includes switch portions 602A connected together and supplying one load 302, although that is not required.

[0148] FIG. 10F is a block diagram depicting another example embodiment of a three-phase system configured to supply power to one or more auxiliary loads 301 and 302 using modules 108IC-1, 108IC-2, and 108IC-3. In this embodiment, modules 108IC-1 and 108IC-2 are configured in the same manner as described with respect to FIGS. 10D-10E. Module 108IC-3 is configured in a simple auxiliary role and does not actively inject voltage or current into any array 700 of system 100. In this embodiment, module 108IC-3 may have converters 202B, C (FIGS. 6B-6C) configured like module 108C of FIG. 3B with one or more auxiliary switch portions 602A but omitting switch portion 601. Thus, one or more energy sources 206 of module 108IC-3 are interconnected in parallel with those of modules 108IC-1 and 108IC-2, and thus this embodiment of system 100 is configured with additional energy to supply auxiliary loads 301 and 302 and to maintain charge on sources 206A of modules 108IC-1 and 108IC-2 through the parallel connection with source 206 of module 108IC-3.

[0149] The energy source 206 of each IC module can be at the same voltage and capacity as the sources 206 of the other modules 108-1-108-N in the system, but that is not required. For example, a relatively high capacity may be desirable in embodiments where one module 108 applies energy to multiple arrays 700 (FIG. 10A), allowing the IC module to discharge at the same rate as the modules in the phased array itself. If module 108 also supplies an auxiliary load, even more capacity may be desired to allow the IC module to both supply the auxiliary load and discharge at relatively the same rate as the other modules. Exemplary Embodiments of Topologies for Applications with Intermittent Charging

[0150] Exemplary embodiments of a modular energy system 100 for use in applications with intermittently available charging sources are described with reference to FIGS. 11A-16. These embodiments can be implemented with any aspect of the system 100 described with reference to FIGS. 1A-10F, unless otherwise stated or logically possible. Accordingly, many variations already described will not be repeated with respect to the following embodiments. These exemplary embodiments are particularly suitable for mobile applications, such as electric motor vehicles operating on rails (rail-based EVs), such as railcars, trams, streetcars, and other freight vehicles, where charging sources are intermittently available. Embodiments can also be used in conjunction with other vehicles, such as cars, buses, trucks, marine vehicles (e.g., electric ferries), airplanes, and even in some stationary applications. Therefore, for ease of explanation, the exemplary embodiments will be described in the context of rail-based EVs, particularly trams or railcars, with the understanding that the embodiments have much broader applicability to other vehicles and applications.

[0151] The exemplary embodiments can be implemented in various configurations for storing and delivering energy while a tram travels through a section of rail where a charging source is not available. Figure 11A is an illustration depicting a portion of an exemplary route of a tram 1100 traveling on rail 1105, where the tram 1100 is traveling from a first location, stop-A, to a second location, stop-B. A charging source is available within Zone-A, which surrounds Stop-A, and a charging source is also available within Zone-B, which surrounds Stop-B. The charging source can be located overhead, at ground level, or underground. When within Zone-A and Zone-B, the tram 1100, whether moving or stationary, can extend an electrical contact device (e.g., a pantograph for the overhead wires) and connect to a charging source to receive power to operate the tram's 1100 loads and to charge the energy source 206 of the system 100. Zone-N bounds the length of rail 1105 between Zone-A and Zone-B where no charging source is available. When traveling through Zone-N, the contact device can be retracted and the tram 1100 will use energy stored in one or more of its systems 100 to provide power for all loads within the tram 1100.

[0152] A streetcar 1100 can be configured with one or more iterations of system 100, each with its own control system 102, and each iteration of system 100 can supply one or more loads, such as a motor load and an auxiliary load. A streetcar can have a single iteration of system 100, with one or more subsystems 1000 supplying power for all loads in all passenger cars. One or more subsystems 1000 can share one control system 102 (e.g., a single MCD 112 for all subsystems 1000) or can have independent control systems 102. Each passenger car can have one or more subsystems 1000 of system 100 to supply the loads in that car, or a car can rely entirely on power supplied by a subsystem 1000 in another passenger car. A combination of approaches can also be used, where a particular coach may have a subsystem 1000 to supply certain loads on that particular coach, and that particular coach may also have other loads that receive power from another subsystem 1000 in a different coach.

[0153] 11B is a block diagram depicting an example embodiment of a streetcar 1100 having two passenger cars 1101 and 11020 with an interconnection 1103 therebetween. System 100 is located in the first passenger car 1101, which has a retractable conductor 1104 for receiving an electrical charge from a charging source 150 when conductor 1104 contacts source 150. System 100 can be configured to supply high-voltage polyphase power to one or more motors in each passenger car 1101 and 1102. Here, system 100 has multiple arrays (not shown) for providing three-phase power (PA, PB, PC) to motors 1110-1A-1110-XA of passenger car 1101 via line 1111, where X can be any integer number greater than or equal to 2. Line 1111 continues through interconnect 1103 to coach 1102 so that three-phase power can be supplied to motors 1110-1B-1110-XB of coach 1102.

[0154] System 100 can also be configured to supply multiple voltages for auxiliary loads, each having different power requirements, including polyphase power, single-phase power, and DC power at one or more voltages. Examples of auxiliary loads include compressors for HVAC systems, battery thermal management systems (BTMS), on-board electrical networks for powering all automated aspects of tram 1100, and others. Here, system 100 is configured to supply three-phase power (PD, PE, PF) to three-phase auxiliary load 1112-1 via line 1113, single-phase (SP) power (line (L), neutral (N)) to single-phase auxiliary load 1114-1 via line 1115, DC voltage at a first level to auxiliary load 301-1 via line 1117, and DC voltage at a second level to auxiliary load 302-1 via line 1119 (see, e.g., the power supplies for loads 301 and 302, as described with respect to Figures 10D and 10E). Lines 1113, 1115, 1117, and 1119 continue through interconnection 1103 and supply similar loads 1112-2, 1114-2, 301-2, and 302-2 in passenger car 1102. Here, the supply for the loads in coach 1101 is provided in a parallel fashion via the same lines for the loads in coach 1102. In other embodiments, different lines can be used to supply the various loads in each coach 1101 and 1102 in a non-parallel fashion depending on the needs of the implementation.

[0155] One or more motors 1110 (e.g., one, two, three, four, or more) can be affixed to or associated with a bogie, and a rail-based vehicle can have multiple (e.g., two or more) such bogies for every passenger car. Installation of system 100 and its subsystems 1000 can be in close proximity to motors 1110 or anywhere as described herein. FIG. 11C is a side view depicting an exemplary embodiment of a streetcar 1100 with an electrical layout of that described with respect to FIG. 11A. Here, each passenger car includes two bogies 1120, each with two motors 1110 configured to provide motive power for driving axles 1122. System 100 can be physically located within passenger car 1101 and installed in a position that would reside above the passenger's head, as shown here, or, in alternative embodiments, below the passenger's feet or floor. Each coach includes auxiliary loads 1112, 1114, 301, and 302. All motors 1110 and auxiliary loads are supplied by system 100 via the arrows shown (individual lines 1111, 1113, 1115, 1117, and 1119 are omitted for clarity).

[0156] 11D is a block diagram depicting another exemplary embodiment of a streetcar 1100, but with multiple subsystems 1000. Each subsystem 1000 can be configured as a separate pack with a common housing. In this example, coach 1101 includes a first subsystem 1000-1 for supplying power for motors 1110-1 and 1110-2 via a set of lines 1111-1 and a second subsystem 1000-2 for supplying power for motors 1110-3 and 1110-4 via a set of lines 1111-2. Coach 1102 includes a third subsystem 1000-3 for supplying power for motors 1110-5 and 1110-6 via a set of lines 1111-3 and a fourth subsystem 1000-4 for supplying power for motors 1110-7 and 1110-8 via a set of lines 1111-4. Coach 1102 also includes a fifth subsystem 1000-5 for supplying polyphase and / or single-phase power for one or more auxiliary loads, where subsystem 1000-5 supplies three-phase power to auxiliary load 1112 via line 1113 and single-phase power to auxiliary load 1114 via line 1115. Subsystems 1000-1-1000-5 can each be configured to supply DC power for loads 301 and 302 using one or more modules 108IC or 108C (see, e.g., FIGS. 3C and 10A-10F).

[0157] Each subsystem 1000 can be connected to a set of shared lines for sharing DC power, and these lines can cross between coaches 1101 and 1102 through interconnection 1103. Lines 1130 can carry high voltage positive and negative DC signals DC_CS+ and DC_CS−, respectively, from charging source 150 to supply charging voltage to all of the modules 108 of each system 100 when tram 1100 is connected to charging source 150. The shared lines can also exchange lower DC voltages for supplying auxiliary loads 301 and 302. Lines 1131 can carry positive and negative DC signals DC1+ and DC1−, respectively, to supply the lower DC voltage to auxiliary load 301. For example, these lines may be similar to the lines interconnecting ports 3 and 4 of IC module 108IC (and 108C) as described with reference to Figures 3C, 10D, and 10E and may carry the voltage of energy source 206 of the interconnected module 108. Line 1132 may carry positive and negative DC signals DC2+ and DC2-, respectively, to supply a lower DC voltage to auxiliary load 302. For example, these lines may be similar to the lines interconnecting ports 5 and 6 of IC module 108IC (and 108C) as described with reference to Figures 3C, 10D, and 10E and may carry a regulated, stepped-down voltage from source 206.

[0158] 11E is a side view depicting another exemplary embodiment of tram 1100 with an electrical layout of that described with respect to FIG. 11C. Here, subsystems 1000-1-1000-4 each provide power for two motors 1110 associated with axles 1122 of bogie 1120. Subsystem 1000-5 in coach 1102 provides power for loads 1112 and 1114, which are also positioned within coach 1102 but may be located within the other coaches as well. Subsystems 1000-1-1000-4 each connect to shared line 1130 for charging and energy exchange, and to line 1131 for energy exchange and supplying load 301, and to line 1132 for supplying load 302. Similar to the embodiment of FIG. 11B, subsystems 1000-1-1000-5 can each be installed in a position above the passenger's head (as shown here), or below the passenger's feet, or wherever they may reside.

[0159] 11F is a block diagram depicting another exemplary embodiment of a streetcar 1100 with multiple subsystems 1000, but with an auxiliary power converter 1150 instead of auxiliary subsystem 1000-5. Auxiliary converter 1150 can convert the high voltage available on DC line 1130 into single-phase and / or poly-phase power for one or more auxiliary loads of streetcar 1100. In this embodiment, converter 1150 is configured to provide three-phase power for three-phase load 1112 via line 1152 and single-phase power for single-phase load 1114 via line 1154. When connected to a charging source 150, auxiliary converter 1150 can power loads 1112 and 1114 using the DC voltage provided by source 150 via line 1130. 12B, when not connected to source 150, the other subsystems 1000-1-1000-4 can provide power to auxiliary converter 1150 via line 1130 by using bidirectional DC-DC converter 1210 to output DC voltage from ports 7 and 8 onto line 1130. The DC output voltages from each module 108 can be summed onto DC line 1130 to provide sufficient voltage to power auxiliary converter 1150.

[0160] The embodiments of Figures 11B-11F are described with respect to a streetcar 1100 having two passenger cars 1101 and 1102, but can also be extended to freight cars having any number of passenger cars (one, three, four, and more) with any combination of subsystems within each passenger car (e.g., supplying one or more motors 1110, one or more loads 1112, one or more loads 1114, one or more loads 301, and / or one or more loads 302).

[0161] The embodiments of FIGS. 11D-11F can also include one or more conventional high-voltage battery packs connected across lines 1130 (DC_CS+ and DC_CS−) like subsystem 1000. A conventional battery pack can include multiple batteries (e.g., Li-ion) or HED capacitors connected in series and is not configured as a modular cascaded multilevel converter. The conventional battery pack can be used to provide supplemental power for any subsystem 1000 (through shared DC line 1130), for auxiliary converter 1150, directly for motor load 1110 (if connected through an inverter), directly for DC auxiliary loads 301 and 302 (e.g., connected through a DC-DC converter), and / or directly for AC auxiliary loads 1112 and / or 1114 (if connected through a DC-AC converter). The conventional battery pack can be charged by charging source 150 through a DC-DC converter interposed in series on line 1130 between the conventional pack and charging source 150. Alternatively, the intervening DC-DC converter can be omitted and the conventional pack can be selectively disconnected from line 1130 using a switch (e.g., contactor) when charging source 150 is connected, and after disconnection of source 150, the battery pack can be reconnected to line 1130 and charged by one or more subsystems 1000.

[0162] The modules 108A-C and 108IC described herein can be used in conjunction with the tram 1100. Additional exemplary embodiments of module configurations are also described. FIG. 12A is a block diagram depicting an exemplary embodiment of a module 108D configured for use within the tram 1100 system 100. In all embodiments described herein, the module 108D can include any number of energy sources 206, such as one or more batteries, one or more high-energy density (HED) capacitors, and / or one or more fuel cells. When multiple batteries are included, the batteries can have the same or different electrochemistries, as described herein. Similarly, different types of high-energy density capacitors and fuel cells can also be used. Each battery can be a single cell or multiple cells connected in series, parallel, or a combination thereof to reach the desired voltage and current characteristics. As shown in FIG. 12A, the module 108 includes a first source 206A and a second source 206B, which can be different types of batteries (e.g., an LTO battery and an LFP battery, etc.), or one can be a battery and the other can be a HED capacitor, or any other combination as described herein.

[0163] Module 108D includes converter 202B or 202C coupled to energy sources 206A and 206B in a manner similar to that described with respect to module 108B of FIG. 3B. Energy source 206A is coupled to energy buffer 204, which is in turn coupled to unidirectional isolated DC-DC converter 1200. Module 108D includes I / O ports 7 and 8 that connect to charging source signals DC_CS+ and DC_CS−, respectively, via line 1130. These signals are input to DC-AC converter 1202 of converter 1200, where they are converted to high-frequency AC form and then input to transformer and rectifier section 1204.

[0164] Transformer and rectifier section 1204 may include a high-frequency transformer and one phase diode rectifier. The DC voltage on ports 7 and 8 may be lower than the total voltage supplied by the charging source because subsystem 1000 may include many such modules 108 receiving charge simultaneously. Transformer and rectifier section 1204 may modify the voltage of the AC signal from converter 1202 and, if necessary, convert the AC signal back to DC form for charging sources 206A and 206B. Section 1204 also provides high-voltage isolation to the other components 202, 204, 206, and 114 of module 108D.

[0165] The unidirectionality is provided by a diode rectifier, which allows current to be received from charging source 150 and passed to buffer 204, but not output in the opposite manner. For example, if the vehicle has an energy recovery system, upon braking, current from braking can be transported back through power connection 110 to each module 108 and routed to either source 206A or 206B using converters 202B, C. The presence of unidirectional DC-DC isolated converter 1200 (diode rectifier) ​​will prevent recovered energy from returning to the charging source through module 108D via line 1130.

[0166] LCD 114 can monitor the status of converter 1200, specifically converter 1202 and section 1204, via data connections 118-5 and 118-6, respectively. As with other components of module 108E, monitor circuitry for converter 1202 and section 1204 can also be included to measure current, voltage, temperature, faults, and the like. These connections 118-5 and 118-6 can also provide control signals to control the switching of converter 1202 and any active elements within section 1204. Isolation of LCD 114 can be maintained by isolation circuitry (e.g., isolated gate drivers and isolated sensors) present on lines 118-5 and 118-6.

[0167] 12B is a block diagram depicting an exemplary embodiment of module 108E, which is configured similarly to that of module 108D, but which has a bidirectional DC-DC isolated converter 1210 instead of converter 1200, allowing bidirectional energy exchange between source 206 (or power connection 110) and ports 7 and 8 connected to line 1130. Bidirectional converter 1210 can route current from ports 7 and 8 to charging sources 206A and 206B (through converters 202B, C), route current from ports 7 and 8 to power loads (by outputting converters 202B, C to ports 1 and 2), route current from sources 206A and / or 206B to ports 7 and 8 (using converters 202B, C) to power one or more high-voltage auxiliary loads via auxiliary converter 1150 (FIG. 11F), and route current from sources 206A and / or 206B to ports 7 and 8 (via converters 202B, C) to charge other modules 108 in system 100 using line 1130.

[0168] A bidirectional converter 1210 is connected between I / O ports 7 and 8, and a buffer 204 includes a DC-AC converter 1202 connected to a transformer 1206, which in turn is connected to an AC-DC converter 1208. Converter 1202 can convert the DC voltage at ports 7 and 8 to a high-frequency AC voltage, which transformer 1206 can modify to a lower voltage, if necessary, and output the modified AC voltage to AC-DC converter 1208, which can convert the AC signal back to DC form for provision to sources 206A, 206B or module ports 1 and 2. Transformer 1206 can also isolate module components 202, 204, 206, 1208, and 114 from the high voltage at ports 7 and 8. As with other components of module 108E, monitor circuitry for converter 1202, transformer 1206, and converter 1208 can also be included to measure current, voltage, temperature, faults, and the like. LCD 114 can monitor the status of converter 1210, and in particular converter 1202, transformer 1206 (e.g., monitor circuitry or active components associated therewith), and converter 1208, via data connections 118-5, 118-7, and 118-8, respectively. These connections 118-5 and 118-6 can also provide control signals to control the switching of converter 1202 and any controllable elements associated with transformer 1206. Isolation of LCD 114 can be maintained by isolation circuitry (e.g., isolated gate drivers and isolated sensors) present on lines 118-5 and 118-6.

[0169] Additionally, for electrochemical battery sources 206, the length of the charge pulses applied to source 206 by AC-DC converter 1208 can be maintained to have a length, e.g., less than 5 milliseconds, to encourage the electrochemical storage reactions within the battery to occur without significant side reactions that could lead to degradation. The charging methodology can incorporate active feedback from each energy source to ensure that battery degradation, if detected, is mitigated by dropping the voltage, pausing the charging routine for that module, or otherwise. Such pulses can be applied at high C rates (e.g., 5 C to 15 C and above), allowing for fast charging of source 206. The duration and frequency of the charge pulses can be controlled by control system 102. Examples of such techniques that may be used in conjunction with any embodiment described herein are described in International Publication No. WO2020 / 243655, filed May 29, 2020, and entitled "Advanced Battery Charging on Modular Levels of Energy Storage Systems," which is incorporated herein by reference for all purposes.

[0170] FIG. 13A is a schematic diagram depicting an exemplary embodiment of module 108D. Converter 202B is coupled to secondary source 206B and, in other embodiments, can be configured like converter 202C (FIG. 6C). Buffer 204 is here configured as a capacitor. I / O ports 7 and 8 are coupled to LC filter 1302, which is in turn coupled to bidirectional converter 1210, specifically DC-AC converter 1202, which, along with switches S10, S11, S12, and S13, is configured as a full-bridge converter. LC filter 1302 can be a distributed DC filter that can filter harmonics from and to DC line 1130, provide current slowing functionality, and / or perform other functions as desired. The full-bridge output from nodes N1 and N2 is connected to the primary winding of transformer 1206 in section 1204. The secondary winding of transformer 1206 is coupled to nodes N3 and N4 of the diode rectifier of section 1204, which includes diodes D1-D4. The switches of converter 1202 can be semiconductor switches configured as MOSFETs, IGBTs, GaN devices, or others as described herein. LCD 114 or another element of control system 102 can provide switching signals for control of switches S1-S6 and S10-S13. Along with other functions described herein, converter 202B can control and independently route current from ports 7 and 8 to source 206B for charging or to I / O ports 1 and 2 for powering motor load 1110.

[0171] FIG. 13B is a schematic diagram depicting an exemplary embodiment of module 108E. Converter 202B is coupled to secondary source 206B and, in other embodiments, can be configured like converter 202C (FIG. 6C). Buffer 204 is configured as a capacitor. I / O ports 7 and 8 are coupled to LC filter 1302, which is in turn coupled to bidirectional converter 1210, specifically DC-AC converter 1202, which is configured as a full-bridge converter with switches S10, S11, S12, and S13. The full-bridge output from nodes N1 and N2 is connected to the primary winding of transformer 1206. The secondary winding of transformer 1206 is coupled to nodes N3 and N4 of a second full-bridge circuit, configured as AC-DC converter 1208, having switches S14, S15, S16, and S17. The switches of converter 1208 can be semiconductor switches configured as MOSFETs, IGBTs, GaN devices, or others as described herein. LCD 114 or another element of control system 102 can provide switching signals for control of switches S1-S6 and S10-S17. Along with other functions described herein, converter 202B can control and independently route current from ports 7 and 8 to I / O ports 1 and 2 for charging source 206B or for powering a motor load.

[0172] 13C is a schematic diagram depicting another exemplary embodiment of module 108E in which AC-DC converter 1208 is configured as a push-pull converter, with a first terminal of source 206 connected through inductor L2 to one side of a dual secondary winding of transformer 1206, and switches S18 and S19 connected between the other side of the dual secondary winding and a common node (e.g., node 4) that is coupled to the opposite terminal of source 206. The push-pull configuration requires only two switches and is therefore more cost-effective than a full-bridge converter, but the switches have a larger voltage applied across them.

[0173] FIG. 14A is a block diagram depicting an exemplary embodiment of a subsystem 1000 configured to supply three-phase power for two motors 1110-1 and 1110-2 in parallel. This embodiment includes three series arrays 700-PA, 700-PB, and 700-PC, with modules 108 arranged in a cascaded manner, with ports 1 and 2 daisy-chained between the modules, as described elsewhere herein. Subsystem 1000 has three arrays 700-PA, 700-PB, and 700-PC to supply three-phase power to one or more loads 1112 using system ports SIO1, SIO2, and SIO3. In this embodiment and that of FIG. 14B, modules 108 can each be configured as module 108D ( FIG. 12A ) or module 108E ( FIGS. 12B , 13A , 13B ). A neutral terminal signal is available at SIO6(N), if desired. DC voltage signals DC_CS+ and DC_CS−, provided from line 1130, are supplied to subsystem 1000 by system I / O ports SIO4 and SIO5, respectively. Ports 7 and 8 of each of modules 108 are daisy-chained together so that the applied charging source voltage is divided across modules 108-1-108-N of each array 700. As with other embodiments, subsystem 1000 can be configured with N modules 108 in each array 700, where N can be any integer equal to or greater than 2.

[0174] FIG. 14B is a block diagram depicting another example embodiment of subsystem 1000 configured to supply three-phase power for motors 1110-1 and 1110-2 and having modules 108IC-1, 108IC-2, and 108IC-3. Modules 108IC can have interconnected energy sources 206 and can be configured for phase balancing between arrays 700, as described elsewhere herein. Modules 108IC can also be configured to supply DC voltage to lines 1131 and 1132 for one or more auxiliary loads 301 and / or one or more auxiliary loads 302. The example embodiments of FIGS. 14A and 14B can be used as subsystems 1000-1-1000-4, depending on whether each subsystem 1000 is configured to supply power for auxiliary loads and configured with phase balancing capability through interconnected modules 108IC, as described with respect to any of FIGS. 11D and 11E.

[0175] 14C and 14D are schematic diagrams depicting an exemplary embodiment of module 108IC configured for use with the embodiment of FIG. 14B. In this embodiment, module 108IC is configured with a single switch portion 604 configured to connect IO port 1 to either the positive DC voltage of source 206 (port 3) or the negative DC voltage of source 206 (port 4). Switch portion 602A regulates and steps down the voltage of source 206 for provision as an auxiliary load voltage for line 1132. A smoothing capacitor C3 can be placed across ports 5 and 6. Module 108IC is configured with two full-bridge converters similar to that of FIG. 13A, including a bidirectional converter 1210. FIG. 14D depicts another embodiment in which AC-DC converter 1208 is configured as a push-pull converter, similar to the embodiment of FIG. 13B.

[0176] FIG. 15 is a block diagram depicting an example embodiment of a subsystem 1000-5 configured to supply poly-phase, single-phase, and DC power for auxiliary loads on a streetcar 1100. Subsystem 1000-5 has three arrays 700-PD, 700-PE, and 700-PF to supply three-phase power to one or more loads 1112 using system ports SIO1, SIO2, and SIO3. Subsystem 1000-5 has a fourth array 700-PG to supply single-phase power to one or more loads 1114 using system outputs SIO6 (SP(L)) and SIO7 (SP(N)). Subsystem 1000-5 can be configured to supply power in as many different phases as needed through the addition of additional arrays 700. The number of modules 108 in each array can be varied depending on the voltage requirements of the loads. For example, although all arrays 700 are shown here as having N modules 108, the value of N can vary between arrays. Each of the N modules 108 in each array 700 can be configured as module 108D (FIG. 13A) or module 108E (FIG. 13B).

[0177] Each array 700 may also include modules 108IC with interconnected sources 206 for energy sharing and phase-to-phase balancing. Modules 108IC-1-108IC-3 may be configured as in the embodiment described with respect to FIGS. 14A and 14B. FIG. 16 is a block diagram depicting an exemplary embodiment of module 108IC-4 for use in a single-phase array 700-PD. This embodiment is similar to that of FIG. 14A, except that module 108IC-4 includes two switch sections 604-1 and 604-2. Sections 604-1 and 604-2 are configured to independently connect IO ports 1 and 2, respectively, to either V DCL+ (port 3) or V DCL− (port 4). IO port 1 can be connected to port 2 of module 108-N of array 700-PD, as shown in FIG. 15. IO port 2 can serve as a neutral terminal for the power provided by array 700-PD. An LC circuit 1600 can be connected between ports 1 and 2 as shown to provide harmonic filtering.

[0178] In some embodiments, a separate subsystem 1000 may not be required to generate the required three-phase and single-phase voltages for the auxiliary load. In such embodiments, subsystem 1000-5 can be omitted, and an auxiliary power converter can instead be used to generate the three-phase in a single-phase auxiliary load voltage. This auxiliary converter can be connected to the DC charging source line 1130 and can receive power from either the charging source 150 or another subsystem 1000 when the charging source 150 is not connected.

[0179] The use of bidirectional converters 1210 in the modules of subsystems 1000-1-1000-5 allows those subsystems to supply a relatively higher DC voltage across lines 1130 in configurations where large auxiliary loads, such as battery thermal management systems (BTMS), are powered directly from lines 1130. In such cases, the auxiliary loads connected across lines 1130 can be powered directly by the charging source when connected to tram 1100 and then powered by one or more subsystems 1000 that output power from source 206 through bidirectional converters 1210 in each module 108.

[0180] The embodiments disclosed herein are not limited to operation with any particular voltage, current, or power. By way of example and for purposes of context, in one sample implementation, charging source 150 may provide a voltage between 600 and 1,000 V on line 1130. Subsystems 1000-1-1000-4 may each provide a multi-phase voltage, regulated and stabilized by voltage and frequency as required, which may be between 300 and 1,000 V depending on the needs of the motor. An exemplary three-phase auxiliary voltage for load 1112 may be between 300 and 500 V, regulated and stabilized as required. An exemplary single-phase auxiliary voltage for load 1114 may be between 120 and 240 V, regulated and stabilized as required. An exemplary auxiliary voltage for load 301 may be between 48 and 60 V, and an exemplary auxiliary voltage for load 302 may be between 24 and 30 V. Again, these are examples only for purposes of context, and the voltages that the system 100 may provide will vary depending on the needs of the application.

[0181] To maintain a balanced overall system, energy from source 206 of auxiliary subsystem 1000-5 can be transported to any of the (non-auxiliary) subsystems 1000-1-1000-4 using line 1131 and the shared interconnect module connection, and this energy can be used to either charge those subsystems 1000-1-1000-4 or to supply motors. Thus, energy from auxiliary subsystem 1000-5 can be used to power one or more motors even if it is not directly connected to those motors, but rather is indirectly connected to those motors using one or more other subsystems 1000-1-1000-4. Similarly, energy recovered through braking can be shared among subsystems 1000-1-1000-5 using line 1131 and the shared interconnect module connection.

[0182] Various aspects of the present subject matter are described below in elaboration of and / or as a complement to the previously described embodiments, with emphasis on the interrelationship and interchangeability of the following embodiments. In other words, emphasis is placed on the fact that each feature of the embodiments can be combined with any other feature, unless otherwise stated.

[0183] In many embodiments, a modular energy system is provided that is controllable to supply power to a load, the system including a plurality of modules connected together and outputting an AC voltage signal including a superposition of first output voltages from each module, each module including an energy source, a first converter connected to the energy source and configured to generate a first output voltage at a first port of the module, and a second converter connected between a second port of the module and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a second output voltage, and charge the energy source.

[0184] In some embodiments, the first converter includes a plurality of switches, wherein the plurality of switches are configured as a full-bridge converter.

[0185] In some embodiments, the second converter is a DC-DC converter including a transformer configured to isolate the energy source and the first converter from the second port. In the system, the second converter can include a DC-AC converter connected between the second port and the transformer. In the system, the second converter can include a diode rectifier connected between the transformer and the energy source. In the system, the second converter can include an AC-DC converter connected between the transformer and the energy source. In the system, the AC-DC converter can be configured as a full-bridge converter or a push-pull converter. In the system, the second converter can be a unidirectional converter that conducts electricity from the second port to the energy source. In the system, the second converter can be a bidirectional converter that conducts electricity between the second port and the energy source.

[0186] In some embodiments, the multiple modules are connected in series as an array and connected to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module is divided from the total charging source voltage. In this system, the energy source can be a first energy source, and each module can include a second energy source. In this system, the second energy source can be connected to the first converter by an inductor. In this system, the first energy source can be a first type of lithium-ion battery, and the second energy source can be a second type of lithium-ion battery, and the first and second types can be different. In this system, the first energy source can be a battery, and the second energy source can be a high-energy-density (HED) capacitor.

[0187] In some embodiments, each module further includes an energy buffer connected in parallel with the energy source. In this system, the energy buffer can be a capacitor.

[0188] In some embodiments, the system may further include a control system configured to control switching of the first and second converters. In the system, the control system may include a plurality of local control devices associated with the plurality of modules and a master control device communicatively coupled to the plurality of local control devices. In the system, the control system may be configured to control switching of the second converter of each module and exchange energy between the energy sources of the modules.

[0189] In many embodiments, a modular energy system is provided that is controllable to supply power to a load, the system including a first array including a first plurality of modules connected together and outputting a first AC voltage signal including a superposition of output voltages from the first plurality of modules, and a second array including a second plurality of modules connected together and outputting a second AC voltage signal including a superposition of output voltages from the second plurality of modules, each module of the first and second plurality of modules including an energy source, a first converter connected to the energy source and configured to generate an output voltage at a first port of the module, and a second converter connected to a second port of the module and to the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a charging voltage, and charge the energy source.

[0190] In some embodiments, the system may further include a first interconnection module coupled to the first array and a second interconnection module coupled to the second array, each of the first and second interconnection modules including a first port and a second port, an energy source, a first converter connected to the energy source and configured to generate an output voltage at the first port, and a second converter connected to the second port and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a charging voltage, and charge the energy source. In the system, the energy sources of the first and second interconnection modules may be connected in parallel. In the system, the first interconnection module may be configured to supply power for an auxiliary load. In the system, the first interconnection module may include a third port configured to connect the energy source of the first interconnection module to the auxiliary load. In the system, the first interconnection module may include a third port configured to connect the energy source of the first interconnection module through the switch network and inductor of the first interconnection module to an auxiliary load external to the first interconnection module. The system may further include a control system configured to control the first converters of each of the first and second interconnection modules to balance energy between the first array and the second array. The system may further include a control system configured to control the first converters of each of the first and second interconnection modules to balance energy between the first array and the second array.

[0191] In some embodiments, the first converter can include multiple switches. In this system, the multiple switches can be configured as a full-bridge converter.

[0192] In some embodiments, the system can include a DC-DC converter including a transformer configured to isolate the energy source and the first converter from the second port. The system can include a DC-AC converter connected between the second port and the transformer. The system can include a diode rectifier connected between the transformer and the energy source. The system can include an AC-DC converter connected between the transformer and the energy source. The AC-DC converter can be configured as a full-bridge converter or a push-pull converter. The system can include a unidirectional converter that conducts electricity from the second port to the energy source. The system can include a bidirectional converter that conducts electricity between the second port and the energy source.

[0193] In some embodiments, the first plurality of modules are connected in series in a first array and connected to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of the first array is divided down from the total charging source voltage.

[0194] In some embodiments, the energy source is a first energy source, and each module can include a second energy source. In this system, the second energy source can be connected to the first converter by an inductor. In this system, the first energy source can be a first type of lithium-ion battery, and the second energy source can be a second type of lithium-ion battery, and the first and second types can be different. In this system, the first energy source can be a battery, and the second energy source can be a high-energy-density (HED) capacitor.

[0195] In some embodiments, each module of the first plurality of modules, each module of the second plurality of modules, the first interconnect module, and the second interconnect module further include an energy buffer connected in parallel with the energy source. In this system, the energy buffer can be a capacitor.

[0196] In some embodiments, the system further includes a control system configured to control switching of the first and second converters. In the system, the control system can include a plurality of local control devices associated with the plurality of modules and a master control device communicatively coupled to the plurality of local control devices. In the system, the control system can be configured to control switching of the second converter of each module and exchange energy between the energy sources of the modules.

[0197] In many embodiments, a modular energy system is provided that is controllable to supply power to loads of an electric vehicle, the system including a first plurality of modules connected together in first, second, and third arrays, each array configured to output an AC voltage signal including a superposition of output voltages from the modules of that array, and a second plurality of modules connected together in a fourth array, configured to output an AC voltage signal including a superposition of output voltages from the second plurality of modules, the first plurality of modules configured to provide three-phase power to a first auxiliary load of the electric vehicle and the second plurality of modules configured to provide single-phase power to a second auxiliary load of the electric vehicle.

[0198] In some embodiments, the system further includes a plurality of interconnection modules connected to the first, second, third, and fourth arrays. In the system, a first interconnection module of the plurality of interconnection modules can be configured to provide DC power to a third auxiliary load of the electric vehicle. In the system, the first interconnection module can include an energy source and can be configured to connect the energy source to the third auxiliary load. In the system, the first interconnection module can include an energy source and can be configured to connect the energy source to the third auxiliary load through the switch network and inductor of the first interconnection module.

[0199] In some embodiments, each module includes an energy source, a first converter connected to the energy source and configured to generate an output voltage at a first port of the module, and a second converter connected to a second port of the module and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a charging voltage, and charge the energy source. The system may further include a control system configured to control the first converter of each of the plurality of interconnection modules and balance energy among the first, second, third, and fourth arrays. In the system, the modules of the first array may be connected in series to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of the first array is divided down from the total charging source voltage. In the system, the first array, the second array, and the third array may be connected in parallel to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module of each array is divided down from the total charging source voltage.

[0200] In some embodiments, all modules further include an energy buffer. In this system, the energy buffer is a capacitor.

[0201] In some embodiments, the system further includes a control system configured to control each of the modules.

[0202] In many embodiments, a modular energy system is provided that is controllable to supply power to a load, the system including a plurality of modules connected together and outputting an AC voltage signal including a superposition of first output voltages from each module, each module including an energy source, a first converter connected to the energy source and configured to generate the first output voltage at a first port of the module, a second converter connected between a second port of the module and the energy source, and a control system configured to control the first converter and second converter of each module.

[0203] In some embodiments, the control system is configured to control the first converter of each module to output a first output voltage according to a pulse width modulation technique. In this system, the control system can be configured to control the second converter of each module to charge the energy source of the module.

[0204] In some embodiments, the control system is configured to control the second converter of each module to charge the energy source of the module and, in parallel, control the first converter of each module to output a first output voltage. In this system, at least a subset of the modules of the plurality of modules can be connected together in a cascaded manner, such that a first port of each module in the subset is coupled to a first port of another module in the subset and a second port of each module in the subset is coupled to a second port of another module in the subset. In this system, the control system can be configured to control the second converter of a first module in the plurality of modules and the second converter of a second module in the plurality of modules to exchange energy between the energy source of the first module and the energy source of the second module.

[0205] In some embodiments, the second converter of each module of the plurality of modules is a DC-DC converter including a transformer configured to isolate the energy source and the first converter from the second port. In the system, the second converter of each module of the plurality of modules can include a DC-AC converter connected between the second port and the transformer. In the system, the second converter of each module of the plurality of modules can include a diode rectifier connected between the transformer and the energy source. In the system, the second converter of each module of the plurality of modules can include an AC-DC converter connected between the transformer and the energy source. In the system, the AC-DC converter can be configured as a full-bridge converter or a push-pull converter.

[0206] In some embodiments, the energy source is a first energy source, and each module of the plurality of modules includes a second energy source coupled to the first converter using an inductor.

[0207] In some embodiments, the control system includes a plurality of local control devices associated with a plurality of modules, and a master control device communicatively coupled to the plurality of local control devices.

[0208] In some embodiments, the first plurality of modules are connected together in first, second, and third arrays, each configured to output an AC voltage signal including a superposition of output voltages from the modules in that array. The system can further include a second plurality of modules connected together in fourth, fifth, and sixth arrays, each configured to output an AC voltage signal including a superposition of output voltages from the modules in that array. The system can further include a third plurality of modules connected together in a seventh array, each configured to output an AC voltage signal including a superposition of output voltages from the third plurality of modules. In the system, the first plurality of modules can be configured to provide three-phase power to a motor of the electric vehicle, the second plurality of modules can be configured to provide three-phase power to a first auxiliary load of the electric vehicle, and the third plurality of modules can be configured to provide single-phase power to a second auxiliary load of the electric vehicle. In the system, the control system can be configured to control the first converter and the second converter of each module of the second and third pluralities of modules.

[0209] In some embodiments, the system further includes an auxiliary converter coupled to a DC line of the system, the auxiliary converter configured to convert DC power from the DC line to AC power for the auxiliary load. The control system can be configured to control a second converter of each module such that an output DC voltage is applied to the DC line to power the auxiliary converter, and output the DC voltage from a second port of each module.

[0210] In many embodiments, a method for operating a rail-based electric vehicle including a modular energy storage system is provided, the method including: outputting an AC power signal to an electric motor of the rail-based electric vehicle, the AC power signal including multiple first output voltages from multiple modules, each module including an energy source, a first converter coupled to the energy source and configured to output the first output voltage from a first port of the module, and a second converter coupled between the energy source and a second port of the module; applying a charging signal to the electric vehicle, the voltage from the charging signal being applied to the second port of each of the multiple modules; and controlling the second converter of each of the multiple modules to charge the energy source of each module. In the method, the electric vehicle can be in motion while the charging signal is applied.

[0211] The term "module," as used herein, refers to one of two or more devices or subsystems within a larger system. A module can be configured to cooperate with other modules of similar size, function, and physical arrangement (e.g., location of electrical terminals, connectors, etc.). Modules with the same function and energy source can be configured the same (e.g., size and physical arrangement) as all other modules in the same system (e.g., rack or pack), while modules with different functions or energy sources may vary in size and physical arrangement. Each module may be physically removable and interchangeable with other modules in the system (e.g., like a wheel on a car or a blade in an information technology (IT) blade server), but this is not required. For example, a system may be packaged in a common housing that does not allow removal and replacement of any one module without disassembly of the system as a whole. However, any embodiment herein can be configured such that each module is removable and replaceable with other modules in a convenient manner without disassembly of the system, etc.

[0212] The term "master control device" is used broadly herein and does not require the implementation of any specific protocol, such as a master and slave relationship with any other device, such as a local control device.

[0213] The term "output" is used broadly herein and does not exclude functioning in a bidirectional manner as both an output and an input. Similarly, the term "input" is used broadly herein and does not exclude functioning in a bidirectional manner as both an input and an output.

[0214] The terms "terminal" and "port" are used broadly herein and can be either unidirectional or bidirectional, can be input or output, and do not require a specific physical or mechanical structure such as a female or male configuration.

[0215] Different reference numeral designations are used herein. These designations are used to facilitate description of the present subject matter and do not limit the scope of the subject matter. Some figures show multiple instances of the same or similar elements. These elements may be appended with a number or letter in an "-X" format, e.g., 123-1, 123-2, or 123-PA. This -X format does not imply that the elements must be configured identically in each instance, but rather is used to facilitate distinction when referring to elements in the figures. Reference to a genus number without the -X designation (e.g., 123) broadly refers to all instances of the element within the genus.

[0216] Various aspects of the present subject matter are described below with a review of and / or in addition to the previously described embodiments, with emphasis placed on the interrelationships and compatibility of the following embodiments, in other words, the fact that each feature of the embodiments can be combined with any other feature, unless expressly stated otherwise or logically impractical.

[0217] The processing circuitry may include one or more processors, microprocessors, controllers, and / or microcontrollers, each of which may be a discrete or stand-alone chip or distributed among several different chips (and portions thereof). Any type of processing circuitry may be implemented, such as, but not limited to, personal computing architectures (e.g., as used in desktop PCs, laptops, tablets, etc.), programmable gate array architectures, dedicated architectures, custom architectures, and others. The processing circuitry may include digital signal processors, which may be implemented in hardware and / or software. The processing circuitry may execute software instructions stored on memory, which cause the processing circuitry to perform many different actions and control other components.

[0218] The processing circuitry may also implement other software and / or hardware routines. For example, the processing circuitry may interface with communications circuitry to perform analog-to-digital conversion, encoding and decoding, other digital signal processing, multimedia functions, conversion of data to a suitable format (e.g., in-phase and quadrature) for presentation to the communications circuitry, and / or cause the communications circuitry to transmit data (wired or wirelessly).

[0219] Any communication signals described herein may be communicated wirelessly unless stated or logically impractical. Communication circuitry may be included for wireless communication. The communication circuitry may be implemented as one or more chips and / or components (e.g., transmitters, receivers, transceivers, and / or other communication circuitry) that implement wireless communication over a link under an appropriate protocol (e.g., Wi-Fi, Bluetooth, Bluetooth Low Energy, near field communication (NFC), radio frequency identification (RFID), proprietary protocols, and others). One or more other antennas may be included with the communication circuitry as needed to operate with various protocols and circuits. In some embodiments, the communication circuitry may share an antenna for transmission over the link. The RF communication circuitry may include a transmitter and receiver (e.g., integrated as a transceiver) and associated encoder logic.

[0220] The processing circuitry may also be adapted to run an operating system and any software applications and perform other functions thereof not related to processing transmitted and received communications.

[0221] Computer program instructions for performing operations in accordance with the described subject matter may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java®, JavaScript®, Smalltalk, C++, C#, Transact-SQL, XML, PHP, or the like, and conventional procedural programming languages ​​such as the “C” programming language or similar programming languages.

[0222] The memory, storage, and / or computer-readable medium may be shared by one or more of the various functional units present, or may be distributed between two or more of them (e.g., as separate memories present in different chips). A memory may also reside in its own separate chip.

[0223] To the extent that an embodiment disclosed herein includes or operates in connection with a memory, storage, and / or computer-readable medium, then that memory, storage, and / or computer-readable medium is non-transitory. Thus, to the extent that that memory, storage, and / or computer-readable medium is covered by one or more claims, then that memory, storage, and / or computer-readable medium is only non-transitory. The terms "non-transitory" and "tangible" as used herein are intended to describe memory, storage, and / or computer-readable medium that exclude propagating electromagnetic signals, but are not intended to limit the type of memory, storage, and / or computer-readable medium in terms of persistence of storage or otherwise. For example, "non-transitory" and / or "tangible" memory, storage, and / or computer-readable media encompass volatile and non-volatile media such as random-access media (e.g., RAM, SRAM, DRAM, FRAM, etc.), read-only media (e.g., ROM, PROM, EPROM, EEPROM, Flash, etc.), and combinations thereof (e.g., hybrid RAM and ROM, NVRAM, etc.) and variants thereof.

[0224] It should be noted that all features, elements, components, functions, and steps described with respect to any embodiment provided herein are intended to be freely combinable and substituted with those from any other embodiment. If a feature, element, component, function, or step is described with respect to only one embodiment, it should be understood that that feature, element, component, function, or step can be used in conjunction with all other embodiments described herein unless explicitly stated otherwise. This paragraph therefore serves as a prior basis and written support for the introduction of claims that, at any time, combine features, elements, components, functions, and steps from different embodiments or substitute features, elements, components, functions, and steps from one embodiment with those of another embodiment, even if the following description does not explicitly state that such combinations or substitutions are possible in a particular instance. In particular, it is expressly acknowledged that an explicit description of all possible combinations and substitutions would be overly burdensome, given that the permissibility of all such combinations and substitutions would be readily recognized by one skilled in the art.

[0225] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0226] While the embodiments are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are described in detail herein. It should be understood, however, that these embodiments are not limited to the particular forms disclosed, but on the contrary, these embodiments are intended to cover all modifications, equivalents, and alternatives falling within the spirit of the disclosure. Furthermore, negative limitations may be set forth in or added to the claims that define the scope of any feature, function, step, or element of the embodiments, as well as any feature, function, step, or element not within the scope of the claimed invention.

Claims

1. 1. A modular energy system controllable to supply electrical power to a load, comprising: a plurality of modules connected together to output an AC voltage signal comprising a superposition of a first output voltage from each module, each module comprising: An energy source, a first converter connected to the energy source and configured to generate the first output voltage at a first port of the module; a second converter connected between a second port of the module and the energy source, the second converter configured to receive a charging signal at the second port, convert the charging signal to a second output voltage, and charge the energy source; a plurality of modules comprising: a control system configured to control the switching of the first and second converters, the control system configured to control the switching of the second converter of each module and to exchange energy between the energy sources of the modules; A system comprising:

2. The system of claim 1 , wherein the first converter comprises a plurality of switches.

3. The system of claim 2 , wherein the plurality of switches are configured as a full-bridge converter.

4. 10. The system of claim 1, wherein the second converter is a DC-DC converter comprising a transformer configured to isolate the energy source and the first converter from the second port.

5. The system of claim 4 , wherein the second converter comprises a DC-AC converter connected between the second port and the transformer.

6. The system of claim 5 , wherein the second converter comprises a diode rectifier connected between the transformer and the energy source.

7. The system of claim 4 , wherein the second converter comprises an AC-DC converter connected between the transformer and the energy source.

8. The system of claim 7 , wherein the AC-DC converter is configured as a full-bridge converter or a push-pull converter.

9. The system of claim 4 , wherein the second converter is a unidirectional converter that conducts electricity from the second port to the energy source.

10. The system of claim 4 , wherein the second converter is a bidirectional converter that conducts electricity between the second port and the energy source.

11. 2. The system of claim 1, wherein the plurality of modules are connected in series as an array and connected to receive a total charging source voltage such that the voltage of the charging signal applied to the second port of each module is divided down from the total charging source voltage.

12. The system of any preceding claim, wherein the energy source is a first energy source and each module comprises a second energy source.

13. The system of claim 12 , wherein the second energy source is connected to the first converter by an inductor.

14. 13. The system of claim 12, wherein the first energy source is a lithium ion battery of a first type and the second energy source is a lithium ion battery of a second type, the first and second types being different.

15. The system of claim 12 , wherein the first energy source is a battery and the second energy source is a high energy density (HED) capacitor.

16. The system of any one of claims 1 to 11, wherein each module further comprises an energy buffer connected in parallel with the energy source.

17. The system of claim 16 , wherein the energy buffer is a capacitor.

18. The system of claim 1 , wherein the control system comprises a plurality of local control devices associated with the plurality of modules, and a master control device communicatively coupled to the plurality of local control devices.

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